Apparatus and method for inspecting articles

ABSTRACT

Method and apparatus for inspecting articles with multiple elements to determine if the elements are properly located, which includes pinching at least a portion of the article including at least some of the elements at an inspection station; irradiating the pinched portions of the article and elements at the inspection station with a radiation source; and capturing an image of the pinched, irradiated elements and article with an image capturing device.

BACKGROUND OF THE INVENTION

[0001] The present invention relates generally to apparatus and methodsfor making and inspecting pre-assembled articles, and more particularlyto apparatus and methods for inspecting such articles.

[0002] Articles such as disposable absorbent garments have numerousapplications including diapers, training pants, feminine care products,and adult incontinence products. A typical disposable absorbent garmentis formed as a composite structure including an absorbent assemblydisposed between a liquid permeable bodyside liner and a liquidimpermeable outer cover. These components can be combined with othermaterials and features such as elastic materials and containmentstructures to form a product which is specifically suited to itsintended purposes. A number of such garments include fasteningcomponents which are intended to be connected together (e.g.,pre-fastened) during manufacture of the garment so that the product ispackaged in its fully assembled form.

[0003] For example, one such pre-fastened garment is a child's trainingpants, which have a central absorbent chassis and front and back sidepanels extending laterally out from the chassis adjacent longitudinallyopposite ends thereof. A portion of each of the front and back sidepanels has a respective fastening component disposed thereon. Duringmanufacture of the training pants, the central absorbent chassis isinitially formed generally flat and then folded over so that the frontand back side panels face each other. In pants that have fasteningcomponents, the respective fastening components of the front and backside panels are then aligned and connected together to define anengagement seam. Upon securing the front and back side panel fasteningcomponents together, the pre-fastened pair of training pants is in itsfully assembled three-dimensional form having an interior space boundedin part by the engagement seam.

[0004] For quality control purposes, it is often desirable to monitorthe presence of and/or interrelationships between one or more elementsof a disposable absorbent garment. For instance, elements such as outercovers, liners, absorbent pads, side panels, elastic components,fastener components, etc. must be positioned or aligned with respect toeach other and/or to other components as desired or otherwise intendedin order to produce an acceptable product. Accordingly, inspectionsystems are commonly used to detect the presence and/or relativepositions of such components during manufacturing. If an inspectionsystem determines that one or more components are out of position andthus do not properly register with other components, the inspectionsystem typically outputs one or more signals indicating that certainarticles should be culled and discarded, that the process should beadjusted so as to bring out-of-position components into proper position,that the process should be adjusted so that subsequent components arebrought into proper registration with one another, etc.

[0005] One such registration inspection system is disclosed in U.S. Pat.No. 5,359,525, the disclosure of which is incorporated herein byreference. As described therein, registration inspection of a compositeproduct during fabrication is accomplished by producing an image of thearticle and then analyzing the image to detect the relative positions ofone or more components. The detected positions are then compared todesired positions to thereby determine whether one or more componentsare improperly positioned. This registration inspection system employsconventional video cameras for capturing visible and ultraviolet lightreflected by and/or transmitted through components of the product inorder to produce still video images of such components. Thus, afterproducing a video image of a composite article and its severalcomponents, the image can be analyzed to determine whether thecomponents are properly positioned and registered with one another.

[0006] Although highly useful for many applications, the inspectionsystem disclosed in the aforementioned patent has certain shortcomingswith respect to the inspection of engagement seams formed by connectingtwo elements together such that the engagement seam is essentially twolayers. For example, formation of engagement seams formed by connectedside panels of the training pants described previously has heretoforeentailed connecting the side panels in face-to-face relationships withouter edges of the side panels aligned with each other. To inspect suchan engagement seam, it was necessary only to inspect the exposed outeredges of the side panels so that there was no need to actually capturean image of any underlying elements or edges of the training pants.

[0007] However, more recent engagement seams are formed by connectingthe side panels in overlapping relationship so that the outer edge ofone side panel underlies the other side panel at the engagement seam.One problem associated with inspecting such seams is that the lap seamis not held flat against the light source. This may cause the image toappear fuzzy because the seam is not at the correct focal length for thecamera. A second problem is the seam not lying flat against itself. Themachine vision system camera captures a two dimensional image of theseam. Therefore, if the seam is not flat, the seam overlap may appearsmaller than it actually is.

SUMMARY OF THE INVENTION

[0008] The present invention overcomes the above described difficultiesand disadvantages of the prior art by providing method and apparatus forinspecting such articles by pinching the articles in an inspectionstation by various means so that a clear image of the article can beobtained by an image capturing device disposed in the inspectionstation.

[0009] More specifically, one aspect of the present invention is theprovision of a method of inspecting an article with multiple elements todetermine if the elements are properly located, the method comprising:pinching at least a portion of the article including at least some ofthe elements at an inspection station; irradiating the pinched portionof the article and the pinched elements at the inspection station with aradiation source; and capturing an image of the pinched, irradiatedportion of the article and the pinched, irradiated elements with animage capturing device.

[0010] In another aspect of the present invention, apparatus forinspecting an article with multiple elements to determine if theelements are properly located is provided, comprising: means forpinching at least a portion of the article including at least some ofthe elements at an inspection station; means for irradiating the pinchedportion of the article and the pinched elements at the inspectionstation; and means for capturing an image of the pinched, irradiatedportion of the article and the pinched, irradiated elements.

[0011] In yet a further aspect of the present invention, apparatus forinspecting an article with multiple elements to determine if theelements are properly located is provided, comprising: a conveyingsystem forming a nip through which the article passes and which is soconstructed and arranged as to pinch at least a portion of the articleand at least some of the multiple elements as they pass therethrough; aradiation source disposed adjacent the nip and which is mounted andarranged so as to irradiate the at least a portion of the article and atleast some of the elements as they pass through the nip; and an imagecapturing device disposed adjacent the nip and which is mounted andarranged so as to capture an image of the irradiated at least a portionof the article and at least some of the elements as they pass throughthe nip.

[0012] Definitions

[0013] Within the context of this specification, each term or phrasebelow will include the following meaning or meanings.

[0014] “Bonded” refers to the joining, adhering, connecting, attaching,or the like, of two elements. Two elements will be considered to bebonded together when they are bonded directly to one another orindirectly to one another, such as when each is directly bonded tointermediate elements.

[0015] “Comprising” is inclusive or open-ended and does not excludeadditional, unrecited elements or method steps.

[0016] “Connected” refers to the joining, adhering, bonding, attaching,or the like, of two elements. Two elements will be considered to beconnected together when they are connected directly to one another orindirectly to one another, such as when each is directly connected tointermediate elements.

[0017] “Disposable” refers to articles which are designed to bediscarded after a limited use rather than being laundered or otherwiserestored for reuse.

[0018] “Disposed,” “disposed on,” and variations thereof are intended tomean that one element can be integral with another element, or that oneelement can be a separate structure bonded to or placed with or placednear another element.

[0019] “Elastic,” “elasticized” and “elasticity” mean that property of amaterial or composite by virtue of which it to recover its original sizeand shape after removal of a force causing a deformation.

[0020] “Elastomeric” refers to a material or composite which can beelongated by at least 25 percent of its relaxed length and which willrecover, upon release of the applied force, at least 10 percent of itselongation. It is generally preferred that the elastomeric material orcomposite be capable of being elongated by at least 100 percent, morepreferably by at least 300 percent, of its relaxed length and recover,upon release of an applied force, at least 50 percent of its elongation.

[0021] “Fabrics” is used to refer to all of the woven, knitted andnonwoven fibrous webs.

[0022] “Flexible” refers to materials which are compliant and which willreadily conform to the general shape and contours of the wearer's body.

[0023] “Force” includes a physical influence exerted by one body onanother which produces acceleration of bodies that are free to move anddeformation of bodies that are not free to move. Force is expressed ingrams per unit area.

[0024] “Graphic” refers to any design, pattern, or the like that isvisible on an absorbent article.

[0025] “Hydrophilic” describes fibers or the surfaces of fibers whichare wetted by the aqueous liquids in contact with the fibers. The degreeof wetting of the materials can, in turn, be described in terms of thecontact angles and the surface tensions of the liquids and materialsinvolved. Equipment and techniques suitable for measuring thewettability of particular fiber materials or blends of fiber materialscan be provided by a Cahn SFA-222 Surface Force Analyzer System, or asubstantially equivalent system. When measured with this system, fibershaving contact angles less than 90° are designated “wettable” orhydrophilic, while fibers having contact angles greater than 90° aredesignated “nonwettable” or hydrophobic.

[0026] “Integral” is used to refer to various portions of a singleunitary element rather than separate structures bonded to or placed withor placed near one another.

[0027] “Inward” and “outward” refer to positions relative to the centerof an absorbent article, and particularly transversely and/orlongitudinally closer to or away from the longitudinal and transversecenter of the absorbent article.

[0028] “Layer” when used in the singular can have the dual meaning of asingle element or a plurality of elements.

[0029] “Liquid impermeable”, when used in describing a layer ormulti-layer laminate, means that a liquid, such as urine, will not passthrough the layer or laminate, under ordinary use conditions, in adirection generally perpendicular to the plane of the layer or laminateat the point of liquid contact. Liquid, or urine, may spread or betransported parallel to the plane of the liquid impermeable layer orlaminate, but this is not considered to be within the meaning of “liquidimpermeable” when used herein.

[0030] “Longitudinal” and “transverse” have their customary meaning. Thelongitudinal axis lies in the plane of the garment and is generallyparallel to a vertical plane that bisects a standing wearer into leftand right body halves when the article is worn. The transverse axis liesin the plane of the article generally perpendicular to the longitudinalaxis. The garment as illustrated is longer in the longitudinal directionthan in the transverse direction.

[0031] “Member” when used in the singular can have the dual meaning of asingle element or a plurality of elements.

[0032] “Nonwoven” and “nonwoven web” refer to materials and webs ofmaterial which are formed without the aid of a textile weaving orknitting process.

[0033] “Operatively joined,” with reference to the attachment of anelastic member to another element, means that the elastic member whenattached to or connected to the element, or treated with heat orchemicals, by stretching, or the like, gives the element elasticproperties; and with reference to the attachment of a non-elastic memberto another element, means that the member and element can be attached inany suitable manner that permits or allows them to perform the intendedor described function of the joinder. The joining, attaching, connectingor the like can be either directly, such as joining either memberdirectly to an element, or can be indirectly by means of another memberdisposed between the first member and the first element.

[0034] “Outer cover graphic” refers to a graphic that is directlyvisible upon inspection of the exterior surface of a garment, and for arefastenable garment is in reference to inspection of the exteriorsurface of the garment when the fastening system is engaged as it wouldbe during use.

[0035] “Permanently bonded” refers to the joining, adhering, connecting,attaching, or the like, of two elements of an absorbent garment suchthat the elements tend to be and remain bonded during normal useconditions of the absorbent garment.

[0036] “Refastenable” refers to the property of two elements beingcapable of releasable attachment, separation, and subsequent releasablereattachment without substantial permanent deformation or rupture.

[0037] “Releasably attached,” “releasably engaged” and variationsthereof refer to two elements being connected or connectable such thatthe elements tend to remain connected absent a separation force appliedto one or both of the elements, and the elements being capable ofseparation without substantial permanent deformation or rupture. Therequired separation force is typically beyond that encountered whilewearing the absorbent garment.

[0038] “Rupture” means the breaking or tearing apart of a material; intensile testing, the term refers to the total separation of a materialinto two parts either all at once or in stages, or the development of ahole in some materials.

[0039] “Stretch bonded” refers to an elastic member being bonded toanother member while the elastic member is extended at least about 25percent of its relaxed length. Desirably, the term “stretch bonded”refers to the situation wherein the elastic member is extended at leastabout 100 percent, and more desirably at least about 300 percent, of itsrelaxed length when it is bonded to the other member.

[0040] “Stretch bonded laminate” refers to a composite material havingat least two layers in which one layer is a gatherable layer and theother layer is an elastic layer. The layers are joined together when theelastic layer is in an extended condition so that upon relaxing thelayers, the gatherable layer is gathered.

[0041] “Surface” includes any layer, film, woven, nonwoven, laminate,composite, or the like, whether pervious or impervious to air, gas,and/or liquids.

[0042] “Tension” includes a uniaxial force tending to cause theextension of a body or the balancing force within that body resistingthe extension.

[0043] “Thermoplastic” describes a material that softens when exposed toheat and which substantially returns to a nonsoftened condition whencooled to room temperature.

[0044] These terms may be defined with additional language in theremaining portions of the specification.

BRIEF DESCRIPTION OF THE DRAWINGS

[0045]FIG. 1 is a side elevation of a child's training pants with afastening system of the training pants shown connected on one side ofthe training pants and disconnected on the other side of the trainingpants;

[0046]FIG. 2 is a bottom plan view of the training pants of FIG. 1 in anunfastened, stretched and laid flat condition to show an outer surfaceof the training pants which faces away from the wearer;

[0047]FIG. 3 is a top plan view of the training pants in its unfastened,stretched and laid flat condition to show an inner surface of thetraining pants which faces the wearer when the training pants are worn,with portions of the training pants being cut away to reveal underlyingfeatures;

[0048]FIG. 4 is a schematic of an assembly section of apparatus formaking articles such as training pants;

[0049]FIG. 5 is a schematic side elevation of a folding section of theapparatus for making articles such as training pants;

[0050]FIG. 6 is a schematic side elevation of a seaming section of theapparatus for making articles such as training pants;

[0051]FIG. 7 is a schematic of a portion of a continuously movingassemblage at one location along the assembly section of FIG. 4;

[0052]FIG. 8 is an enlarged side elevation of the folding section ofFIG. 5;

[0053]FIG. 9 is a top plan view of a portion of the folding section ofFIG. 5;

[0054]FIG. 10 is an enlarged section view of a portion of a pair oftraining pants at a location within the folding section of FIG. 5;

[0055]FIG. 11 is an enlarged side elevation of an upstream portion ofthe seaming section of FIG. 6;

[0056]FIG. 12 is a partial section taken in the plane of line 12-12 ofFIG. 11;

[0057]FIG. 13 is a partial section taken in the plane of line 13-13 ofFIG. 11;

[0058]FIG. 14 is a partial section taken in the plane of line 14-14 ofFIG. 11;

[0059]FIG. 15 is a partial section taken in the plane of line 15-15 ofFIG. 11;

[0060]FIG. 16 is a partial section taken in the plane of line 16-16 ofFIG. 11;

[0061]FIG. 17 is a schematic representation of the upper and scrunchconveyors with the radiation source above the upper conveyor and theimage capturing device below the scrunch conveyor;

[0062]FIG. 18 is a schematic representation of the upper and scrunchconveyors with the radiation source and the image capturing device belowthe scrunch conveyor;

[0063]FIG. 19 is a schematic representation of the upper alignmentconveyor and the nip roller with the radiation source above the upperalignment conveyor and the image capturing device inside the nip roller;and

[0064]FIG. 20 is a schematic representation of the upper alignmentconveyor and the nip roller with the radiation source and the imagecapturing device inside the nip roller.

DETAILED DESCRIPTION OF THE DRAWINGS

[0065] The methods and apparatus of the present invention can be used tomake a variety of pre-fastened articles such as disposable absorbentgarments including diapers, training pants, feminine hygiene products,incontinence products, other personal care or health care garments, swimpants, athletic clothing, pants and shorts, and the like. Moreparticularly, the methods and apparatus of the present invention can beused to make articles in which at least two elements of the article areconnected together during the making thereof to assemble or “pre-fasten”the article. For ease of explanation, the methods and apparatus of thepresent invention are hereafter described in connection with makingpre-fastened child's training pants, generally indicated as 20 inFIG. 1. In particular, the methods and apparatus will be described interms of those for making pre-fastened disposable training pants asdescribed in U.S. patent application Ser. No. 09/444,083 titled“Absorbent Articles With Refastenable Side Seams” and filed Nov. 22,1999 (corresponding to PCT application WO 00/37009 published Jun. 29,2000) by A. L. Fletcher et al., the disclosure of which is incorporatedherein by reference. Training pants 20 can also be constructed using themethods and apparatus disclosed in U.S. Pat. No. 4,940,464 issued Jul.10, 1990 to Van Gompel et al.; and U.S. Pat. No. 5,766,389 issued Jun.16, 1998 to Brandon et al.; the disclosures of which are alsoincorporated herein by reference.

[0066] With reference now to the drawings, and in particular to FIG. 1,the training pants 20 are illustrated in a partially fastened conditionand comprise an absorbent chassis 32 having a front waist region 22, aback waist region 24, a crotch region 26 interconnecting the front andback waist regions, an inner surface 28 which is configured to contactthe wearer, and an outer surface 30 opposite the inner surface andconfigured to contact the wearer's clothing. With additional referenceto FIGS. 2 and 3, the absorbent chassis 32 also has a pair of laterallyopposite side edges 36 and a pair of longitudinally opposite waistedges, respectively designated front waist edge 38 and back waist edge39. The front waist region 22 is contiguous with the front waist edge38, and the back waist region 24 is contiguous with the back waist edge39.

[0067] The illustrated absorbent chassis 32 comprises a compositestructure 33 (FIG. 3), which when laid flat can be rectangular or anyother desired shape, and has a pair of laterally opposite front sidepanels 34 and a pair of laterally opposite back side panels 134extending outward therefrom. The composite structure 33 and side panels34, 134 may comprise two or more separate elements, as shown in FIG. 1,or be integrally formed. Integrally formed side panels 34, 134 andcomposite structure 33 would comprise at least some common materials,such as the bodyside liner, flap composite, outer cover, other materialsand/or combinations thereof, and/or could define a one-piece elastic,stretchable, or nonstretchable pants. The illustrated compositestructure 33 comprises an outer cover 40, a bodyside liner 42 (FIGS. 1and 3) connected to the outer cover in a superposed relation, anabsorbent assembly 44 (FIG. 3) disposed between the outer cover and thebodyside liner, and a pair of containment flaps 46 (FIG. 3). Theillustrated composite structure 33 has opposite ends 45 which formportions of the front and back waist edges 38 and 39, and opposite sideedges 47 which form portions of the side edges 36 of the absorbentchassis 32 (FIGS. 2 and 3). For reference, arrows 48 and 49 depict theorientation of the longitudinal axis and the transverse or lateral axis,respectively, of the training pants 20.

[0068] With the training pants 20 in the fastened position as partiallyillustrated in FIG. 1, the front and back side panels 34, 134 areconnected together by a fastening system 80 to define athree-dimensional pants configuration having an interior space 51, awaist opening 50 for receiving the wearer into the interior space of thepants, a pair of leg openings 52 and engagement seams 88 along which theside panels are connected. The interior space 51 of the pants 20 is thusbounded by the absorbent chassis 32, the engagement seams 88 and theportions of the side panels 34, 134 extending on opposite sides of theengagement seams 88 (e.g., between the engagement seams and theabsorbent chassis. As used herein, the “interior space” 49 is intendedto refer to the space between any two portions of a three-dimensionalarticle which generally oppose each. It is understood that a transversecross-section of the article need not be closed, e.g., continuous, todefine an interior space. For example, a two-dimensional article may begenerally folded over on itself so that two portions of the articleoppose each other to define an interior space of the articletherebetween. Thus, the interior space 51 of the training pants 20 shownin FIG. 1 may be defined by the side panels 34, 134 themselves or, ifthe side panels were fully straightened therebetween, the interior spacewould be defined by a combination of the side panels and the front andback waist regions 22, 24 of the absorbent chassis 32.

[0069] The front waist region 22 comprises the portion of the trainingpants 20 which, when worn, is positioned on the front of the wearerwhile the back waist region 24 comprises the portion of the trainingpants which, when worn, is positioned on the back of the wearer. Thecrotch region 26 of the training pants 20 comprises the portion of thetraining pants 20 which, when worn, is positioned between the legs ofthe wearer and covers the lower torso of the wearer. The front and backside panels 34 and 134 comprise the portions of the training pants 20which, when worn, are positioned on the hips of the wearer. The waistedges 38 and 39 of the absorbent chassis 32 are configured to encirclethe waist of the wearer when worn and together define the waist opening50 (FIG. 1). Portions of the side edges 36 in the crotch region 26generally define the leg openings 52.

[0070] The absorbent chassis 32 is configured to contain and/or absorbany exudates discharged from the wearer. For example, the absorbentchassis 32 desirably although not necessarily comprises the pair ofcontainment flaps 46 which are configured to provide a barrier to thetransverse flow of body exudates. A flap elastic member 53 (FIG. 3) canbe operatively joined with each containment flap 46 in any suitablemanner as is well known in the art. The elasticized containment flaps 46define an unattached edge which assumes an upright configuration in atleast the crotch region 26 of the training pants 20 to form a sealagainst the wearer's body. The containment flaps 46 can be located alongthe side edges 36 of the absorbent chassis 32, and can extendlongitudinally along the entire length of the absorbent chassis or mayonly extend partially along the length of the absorbent chassis.Suitable constructions and arrangements for the containment flaps 46 aregenerally well known to those skilled in the art and are described inU.S. Pat. No. 4,704,116 issued Nov. 3, 1987 to Enloe, which isincorporated herein by reference.

[0071] To further enhance containment and/or absorption of bodyexudates, the training pants 20 desirably although not necessarilyinclude a front waist elastic member 54, a rear waist elastic member 56,and leg elastic members 58, as are known to those skilled in the art(FIG. 3). The waist elastic members 54 and 56 can be operatively joinedto the outer cover 40 and/or the bodyside liner 42 along the oppositewaist edges 38 and 39, and can extend over part or all of the waistedges. The leg elastic members 58 can be operatively joined to the outercover 40 and/or the bodyside liner 42 along the opposite side edges 36and positioned in the crotch region 26 of the training pants 20. The legelastic members 58 can be longitudinally aligned along each side edge 47of the composite structure 33. Each leg elastic member 58 has a frontterminal point 63 and a back terminal point 65, which represent thelongitudinal ends of the elastic gathering caused by the leg elasticmembers. The front terminal points 63 can be located adjacent thelongitudinally innermost parts of the front side panels 34, and the backterminal points 65 can be located adjacent the longitudinally innermostparts of the back side panels 134.

[0072] The flap elastic members 53, the waist elastic members 54 and 56,and the leg elastic members 58 can be formed of any suitable elasticmaterial. As is well known to those skilled in the art, suitable elasticmaterials include sheets, strands or ribbons of natural rubber,synthetic rubber, or thermoplastic elastomeric polymers. The elasticmaterials can be stretched and adhered to a substrate, adhered to agathered substrate, or adhered to a substrate and then elasticized orshrunk, for example with the application of heat, such that elasticconstrictive forces are imparted to the substrate. In one particularembodiment, for example, the leg elastic members 58 comprise a pluralityof dry-spun coalesced multifilament spandex elastomeric threads soldunder the trade name LYCRA® and available from E. I. Du Pont de Nemoursand Company, Wilmington, Del., U.S.A.

[0073] The outer cover 40 desirably comprises a material which issubstantially liquid impermeable, and can be elastic, stretchable ornonstretchable. The outer cover 40 can be a single layer of liquidimpermeable material, but desirably comprises a multi-layered laminatestructure in which at least one of the layers is liquid impermeable. Forinstance, the outer cover 40 can include a liquid permeable outer layerand a liquid impermeable inner layer that are suitably joined togetherby a laminate adhesive, ultrasonic bonds, thermal bonds, or the like.Suitable laminate adhesives, which can be applied continuously orintermittently as beads, a spray, parallel swirls, or the like, can beobtained from Findley Adhesives, Inc., of Wauwatosa, Wis., U.S.A., orfrom National Starch and Chemical Company, Bridgewater, N.J. U.S.A. Theliquid permeable outer layer can be any suitable material and desirablyone that provides a generally cloth-like texture. One example of such amaterial is a 20 gsm (grams per square meter) spunbond polypropylenenonwoven web. The outer layer may also be made of those materials ofwhich the liquid permeable bodyside liner 42 is made. While it is not anecessity for the outer layer to be liquid permeable, it is desired thatit provides a relatively cloth-like texture to the wearer.

[0074] The inner layer of the outer cover 40 can be both liquid andvapor impermeable, or can be liquid impermeable and vapor permeable. Theinner layer can be manufactured from a thin plastic film, although otherflexible liquid impermeable materials may also be used. The inner layer,or the liquid impermeable outer cover 40 when a single layer, preventswaste material from wetting articles, such as bedsheets and clothing, aswell as the wearer and caregiver. A suitable liquid impermeable film foruse as a liquid impermeable inner layer, or a single layer liquidimpermeable outer cover 40, is a 0.02 millimeter polyethylene filmcommercially available from Pliant Plastics of Schaumburg, Ill. U.S.A.

[0075] If the outer cover 40 is a single layer of material, it can beembossed and/or matte finished to provide a more cloth-like appearance.As earlier mentioned, the liquid impermeable material can permit vaporsto escape from the interior space 51 of the disposable absorbentarticle, while still preventing liquids from passing through the outercover 40. A suitable “breathable” material is composed of a microporouspolymer film or a nonwoven fabric that has been coated or otherwisetreated to impart a desired level of liquid impermeability. A suitablemicroporous film is a PMP-1 film material commercially available fromMitsui Toatsu Chemicals, Inc., Tokyo, Japan, or an XKO-8044 polyolefinfilm commercially available from 3M Company, Minneapolis, Minn. U.S.A.

[0076] As shown in FIGS. 1 and 2, the training pants 20 and inparticular the outer cover 40 desirably comprises one or moreappearance-related components. Examples of appearance-related componentsinclude, but are not limited to, graphics; highlighting or emphasizingleg and waist openings in order to make product shaping more evident orvisible to the user; highlighting or emphasizing areas of the product tosimulate functional components such as elastic leg bands, elasticwaistbands, simulated “fly openings” for boys, ruffles for girls;highlighting areas of the product to change the appearance of the sizeof the product; registering wetness indicators, temperature indicators,and the like in the product; registering a back label, or a front label,in the product; and registering written instructions at a desiredlocation in the product.

[0077] The illustrated pair of training pants 20 is designed for use byyoung girls and includes a registered outer cover graphic 60 (FIG. 2).In this design, the registered graphic 60 includes a primary pictorialimage 61, simulated waist ruffles 62, and simulated leg ruffles 64. Theprimary pictorial image 61 includes a rainbow, sun, clouds, animalcharacters, wagon and balloons. Any suitable design can be utilized fora training pants intended for use by young girls, so as to beaesthetically and/or functionally pleasing to them and the caregiver.The appearance-related components are desirably positioned on thetraining pants 20 at selected locations, which can be carried out usingthe methods disclosed in U.S. Pat. No. 5,766,389 issued Jun. 16, 1998 toBrandon et al., the entire disclosure of which is incorporated herein byreference. The primary pictorial image 61 is desirably positioned in thefront waist region 22 along the longitudinal center line of the trainingpants 20.

[0078] The liquid permeable bodyside liner 42 is illustrated asoverlying the outer cover 40 and absorbent assembly 44, and may but neednot have the same dimensions as the outer cover 40. The bodyside liner42 is desirably compliant, soft feeling, and non-irritating to thechild's skin. Further, the bodyside liner 42 can be less hydrophilicthan the absorbent assembly 44, to present a relatively dry surface tothe wearer and permit liquid to readily penetrate through its thickness.Alternatively, the bodyside liner 42 can be more hydrophilic or can haveessentially the same affinity for moisture as the absorbent assembly 44to present a relatively wet surface to the wearer to increase thesensation of being wet. This wet sensation can be useful as a trainingaid. The hydrophilic/hydrophobic properties can be varied across thelength, width and depth of the bodyside liner 42 and absorbent assembly44 to achieve the desired wetness sensation or leakage performance.

[0079] The bodyside liner 42 can be manufactured from a wide selectionof web materials, such as synthetic fibers (for example, polyester orpolypropylene fibers), natural fibers (for example, wood or cottonfibers), a combination of natural and synthetic fibers, porous foams,reticulated foams, apertured plastic films, or the like. Various wovenand nonwoven fabrics can be used for the bodyside liner 42. For example,the bodyside liner can be composed of a meltblown or spunbonded web ofpolyolefin fibers. The bodyside liner can also be a bonded-carded webcomposed of natural and/or synthetic fibers. The bodyside liner can becomposed of a substantially hydrophobic material, and the hydrophobicmaterial can, optionally, be treated with a surfactant or otherwiseprocessed to impart a desired level of wettability and hydrophilicity.For example, the material can be surface treated with about 0.45 weightpercent of a surfactant mixture comprising Ahcovel N-62 from HodgsonTextile Chemicals of Mount Holly, N.C., U.S.A. and GLUCOPON® 220UP fromThe Cognis Group of Ambler, Pa. in an active ratio of 3:1. Thesurfactant can be applied by any conventional means, such as spraying,printing, brush coating or the like. The surfactant can be applied tothe entire bodyside liner 42 or can be selectively applied to particularsections of the bodyside liner, such as the medial section along thelongitudinal center line.

[0080] A suitable liquid permeable bodyside liner 42 is a nonwovenbicomponent web having a basis weight of about 27 gsm. The nonwovenbicomponent can be a spunbond bicomponent web, or a bonded cardedbicomponent web. Suitable bicomponent staple fibers include apolyethylene/polypropylene bicomponent fiber available from CHISSOCorporation, Osaka, Japan. In this particular bicomponent fiber, thepolypropylene forms the core and the polyethylene forms the sheath ofthe fiber. Other fiber orientations are possible, such as multi-lobe,side-by-side, end-to-end, or the like. The outer cover 40, bodysideliner 42 and other materials used to construct the pants can compriseelastomeric or nonelastomeric materials.

[0081] The absorbent assembly 44 (FIG. 3) is positioned between theouter cover 40 and the bodyside liner 42, which can be joined togetherby any suitable means such as adhesives, ultrasonic bonds, thermalbonds, or the like. The absorbent assembly 44 can be any structure whichis generally compressible, conformable, non-irritating to the child'sskin, and capable of absorbing and retaining liquids and certain bodywastes, and may be manufactured in a wide variety of sizes and shapes,and from a wide variety of liquid absorbent materials commonly used inthe art. For example, the absorbent assembly 44 can suitably comprise amatrix of hydrophilic fibers, such as a web of cellulosic fluff, mixedwith particles of a high-absorbency material commonly known assuperabsorbent material. In a particular embodiment, the absorbentassembly 44 comprises a matrix of cellulosic fluff, such as wood pulpfluff, and superabsorbent hydrogel-forming particles. The wood pulpfluff can be exchanged with synthetic, polymeric, meltblown fibers orshort cut homofil bicomponent synthetic fibers and natural fibers. Thesuperabsorbent particles can be substantially homogeneously mixed withthe hydrophilic fibers or can be nonuniformly mixed. The fluff andsuperabsorbent particles can also be selectively placed into desiredzones of the absorbent assembly 44 to better contain and absorb bodyexudates. The concentration of the superabsorbent particles can alsovary through the thickness of the absorbent assembly 44. Alternatively,the absorbent assembly 44 can comprise a laminate of fibrous webs andsuperabsorbent material or other suitable means of maintaining asuperabsorbent material in a localized area.

[0082] Suitable superabsorbent materials can be selected from natural,synthetic, and modified natural polymers and materials. Thesuperabsorbent materials can be inorganic materials, such as silicagels, or organic compounds, such as crosslinked polymers, for example,sodium neutralized polyacrylic acid. Suitable superabsorbent materialsare available from various commercial vendors, such as Dow ChemicalCompany located in Midland, Mich., U.S.A., and Stockhausen GmbH & Co.KG, D-47805 Krefeld, Federal Republic of Germany. Typically, asuperabsorbent material is capable of absorbing at least about 15 timesits weight in water, and desirably is capable of absorbing more thanabout 25 times its weight in water.

[0083] In one embodiment, the absorbent assembly 44 comprises a blend ofwood pulp fluff and superabsorbent material. One preferred type of pulpis identified with the trade designation CR1654, available from U.S.Alliance, Childersburg, Ala., U.S.A., and is a bleached, highlyabsorbent sulfate wood pulp containing primarily soft wood fibers andabout 16 percent hardwood fibers. As a general rule, the superabsorbentmaterial is present in the absorbent assembly 44 in an amount of from 0to about 90 weight percent based on total weight of the absorbentassembly. The absorbent assembly 44 suitably has a density within therange of about 0.10 to about 0.35 grams per cubic centimeter. Theabsorbent assembly 44 may or may not be wrapped or encompassed by asuitable tissue wrap that may help maintain the integrity and/or shapeof the absorbent assembly.

[0084] The absorbent chassis 32 can also incorporate other materialsdesigned primarily to receive, temporarily store, and/or transportliquid along the mutually facing surface with absorbent assembly 44,thereby maximizing the absorbent capacity of the absorbent assembly. Onesuitable material is referred to as a surge layer (not shown) andcomprises a material having a basis weight of about 50 to about 120grams per square meter, and comprising a through-air-bonded-carded webof a homogenous blend of 60 percent 3 denier type T-256 bicomponentfiber comprising a polyester core/polyethylene sheath and 40 percent 6denier type T-295 polyester fiber, both commercially available from KosaCorporation of Salisbury, N.C., U.S.A.

[0085] As noted previously, the illustrated training pants 20 have frontand back side panels 34 and 134 disposed on each side of the absorbentchassis 32. The front side panels 34 can be permanently bonded alongseams 66 to the composite structure 33 of the absorbent chassis 32 inthe respective front and back waist regions 22 and 24. Moreparticularly, as seen best in FIGS. 2 and 3, the front side panels 34can be permanently bonded to and extend transversely outward beyond theside edges 47 of the composite structure 33 in the front waist region22, and the back side panels 134 can be permanently bonded to and extendtransversely outward beyond the side edges of the composite structure inthe back waist region 24. The side panels 34 and 134 may be bonded tothe composite structure 33 using attachment means known to those skilledin the art such as adhesive, thermal or ultrasonic bonding.Alternatively, the side panels 34 and 134 can be formed as an integralportion of a component of the composite structure 33. For example, theside panels can comprise a generally wider portion of the outer cover40, the bodyside liner 42, and/or another component of the absorbentchassis 32. The front and back side panels 34 and 134 can be permanentlybonded together or be releasably connected with one another such as bythe fastening system 80 of the illustrated embodiment.

[0086] The front and back side panels 34, 134 each have an outer edge 68spaced laterally from the seam 66, a leg end edge 70 disposed toward thelongitudinal center of the training pants 20, and a waist end edge 72disposed toward a longitudinal end of the training pants. The leg endedge 70 and waist end edge 72 extend from the side edges 47 of thecomposite structure 33 to the outer edges 68. The leg end edges 70 ofthe side panels 34 and 134 form part of the side edges 36 of theabsorbent chassis 32. In the back waist region 24, the leg end edges 70are desirably although not necessarily curved and/or angled relative tothe transverse axis 49 to provide greater coverage toward the back ofthe pants 20 as compared to the front of the pants. The waist end edges72 are desirably parallel to the transverse axis 49. The waist end edges72 of the front side panels 34 form part of the front waist edge 38 ofthe absorbent chassis 32, and the waist end edges 72 of the back sidepanels 134 form part of the back waist edge 39 of the absorbent chassis.

[0087] In particular embodiments for improved fit and appearance, theside panels 34, 134 desirably have an average length measured parallelto the longitudinal axis 48 which is about 15 percent or greater, andparticularly about 25 percent or greater, of the overall length of thepants, also measured parallel to the longitudinal axis 48. For example,in training pants 20 having an overall length of about 54 centimeters,the side panels 34, 134 desirably have an average length of about 10centimeters or greater, such as about 15 centimeters. While each of theside panels 34, 134 extends from the waist opening 50 to one of the legopenings 52, the illustrated back side panels 134 have a continuallydecreasing length dimension moving from the attachment line 66 to theouter edge 68, as is best shown in FIGS. 2 and 3.

[0088] Each of the side panels 34, 134 can include one or moreindividual, distinct pieces of material. In particular embodiments, forexample, each side panel 34, 134 can include first and second side panelportions that are joined at a seam, or can include a single piece ofmaterial which is folded over upon itself (not shown).

[0089] The side panels 34, 134 desirably although not necessarilycomprise an elastic material capable of stretching in a directiongenerally parallel to the transverse axis 49 of the training pants 20.Suitable elastic materials, as well as one process of incorporatingelastic side panels into training pants, are described in the followingU.S. Pat. Nos. 4,940,464 issued Jul. 10, 1990 to Van Gompel et al.;5,224,405 issued Jul. 6, 1993 to Pohjola; 5,104,116 issued Apr. 14, 1992to Pohjola; and 5,046,272 issued Sep. 10, 1991 to Vogt et al.; all ofwhich are incorporated herein by reference. In particular embodiments,the elastic material comprises a stretch-thermal laminate (STL), aneck-bonded laminate (NBL), a reversibly necked laminate, or astretch-bonded laminate (SBL) material. Methods of making such materialsare well known to those skilled in the art and described in U.S. Pat.No. 4,663,220 issued May 5, 1987 to Wisneski et al.; U.S. Pat. No.5,226,992 issued Jul. 13, 1993 to Morman; and European PatentApplication No. EP 0 217 032 published on Apr. 8, 1987 in the names ofTaylor et al.; all of which are incorporated herein by reference.Alternatively, the side panel material may comprise other woven ornonwoven materials, such as those described above as being suitable forthe outer cover 40 or bodyside liner 42; mechanically pre-strainedcomposites; or stretchable but inelastic materials.

[0090] In particular embodiments, the illustrated training pants 20includes the fastening system 80 for refastenably securing the trainingpants about the waist of the wearer. The illustrated fastening system 80includes first fastening components 82 adapted for refastenableengagement to corresponding second fastening components 84. In oneembodiment, one surface of each of the first fastening components 82comprises a plurality of engaging elements which project from thatsurface. The engaging elements of the first fastening components 82 areadapted to repeatedly engage and disengage engaging elements of thesecond fastening components 84.

[0091] The fastening components can comprise separate elements bonded tothe side panels, or they may be integrally formed with the side panels.Thus, unless otherwise specified, the term “fastening component”includes separate components which function as fasteners, and regions ofmaterials such as the side panels which function as fasteners. Moreover,a single material can define multiple fastening components to the extentthat different regions of the material function as separate fasteners.The fastening components 82, 84 can be located on the side panels,between the side panels such as on the absorbent chassis, or acombination of the two.

[0092] The fastening components 82, 84 can comprise any refastenablefasteners suitable for absorbent articles, such as adhesive fasteners,cohesive fasteners, mechanical fasteners, or the like. In particularembodiments the fastening components comprise mechanical fasteningelements for improved performance. Suitable mechanical fasteningelements can be provided by interlocking geometric shaped materials,such as hooks, loops, bulbs, mushrooms, arrowheads, balls on stems, maleand female mating components, buckles, snaps, or the like.

[0093] The refastenable fastening system 80 allows for easy inspectionof the interior space 51 of the pants 20. If necessary, the fasteningsystem 80 also allows the pants 20 to be removed quickly and easily.This is particularly beneficial when the pants contain messy excrement.For training pants 20, the caregiver can completely remove the pant-likeproduct and replace it with a new one without having to remove thechild's shoes and clothing.

[0094] In the illustrated embodiment, the first fastening components 82comprise hook fasteners and the second fastening components 84 comprisecomplementary loop fasteners. In another particular embodiment, thefirst fastening components 82 comprise loop fasteners and the secondfastening components 84 comprise complementary hook fasteners.Alternatively, the fastening components 82, 84 can comprise interlockingsimilar surface fasteners, adhesive or cohesive fastening elements suchas an adhesive fastener and an adhesive-receptive landing zone ormaterial; or the like. Although the training pants 20 illustrated inFIG. 1 show the back side panels 134 overlapping the front side panels34 upon connection thereto, which is convenient, the training pants 20can also be configured so that the front side panels overlap the backside panels when connected. One skilled in the art will recognize thatthe shape, density and polymer composition of the hooks and loops may beselected to obtain the desired level of engagement between the fasteningcomponents 82, 84. A more aggressive hook material may comprise amaterial with a greater average hook height, a greater percentage ofdirectionally-aligned hooks, or a more aggressive hook shape.

[0095] Loop fasteners typically comprise a fabric or material having abase or backing structure and a plurality of loop members extendingupwardly from at least one surface of the backing structure. The loopmaterial can be formed of any suitable material, such as acrylic, nylon,polypropylene or polyester, polyethylene and can be formed by methodssuch as warp knitting, stitch bonding or needle punching. Loop materialscan also comprise any fibrous structure capable of entangling orcatching hook materials, such as carded, spunbonded or other nonwovenwebs or composites, including elastomeric and nonelastomeric composites.Suitable loop materials are available from Guilford Mills, Inc.,Greensboro, N.C., U.S.A. under the trade designation No. 36549. Anothersuitable loop material can comprise a pattern un-bonded web as disclosedin U.S. Pat. No. 5,858,515 issued Jan. 12, 1999 to Stokes et al.

[0096] Hook fasteners typically comprise a fabric or material having abase or backing structure and a plurality of hook members extendingupwardly from at least one surface of the backing structure. In contrastto the loop fasteners which desirably comprise a flexible fabric, thehook material advantageously comprises a resilient material to minimizeunintentional disengagement of the fastener components as a result ofthe hook material becoming deformed and catching on clothing or otheritems. The term “resilient” as used herein refers to an interlockingmaterial having a predetermined shape and the property of theinterlocking material to resume the predetermined shape after beingengaged and disengaged from a mating, complementary interlockingmaterial. Suitable hook material can be molded or extruded from nylon,polypropylene, polyethylene or another suitable material. Suitablesingle-sided hook materials for the fastening components 82, 84 areavailable from commercial vendors such as Velcro Industries B.V.,Amsterdam, Netherlands or affiliates thereof, and are identified asVelcro HTH-829 with a uni-directional hook pattern and having athickness of about 0.9 millimeters (35 mils) and HTH-851 with auni-directional hook pattern and having a thickness of about 0.5millimeters (20 mils); and Minnesota Mining & Manufacturing Co., St.Paul, Minn. U.S.A., including specific materials identified as CS-600.

[0097] With particular reference to FIG. 3, the fastening components 82are disposed on the inner surface 28 of the back side panels 134. Thefastening components 82 are desirably positioned along the outer edges68 of the back side panels 134, and abutting or adjacent to the waistend edge 72. In certain embodiments, for example, the fasteningcomponents 82 can be spaced inwardly by a distance of about 0 to about25 millimeters, and more particularly within about 1 centimeter, of theouter edges 68, the waist end edges 72, and the leg end edges 70. Withparticular reference to FIG. 2, the second fastening components 84 aredisposed on the outer surface 30 of the front side panels 134. Thesecond fastening components 84 are sized to receive the first fasteningcomponents 82 and are desirably positioned along the outer edges 68 ofthe front side panels 34, and abutting or adjacent to the waist end edge72. As an example, the second fastening components 84 can be locatedwithin about 2 centimeters, and more particularly within about 1centimeter, of the outer edges 68, the waist end edges 72, and the legend edges 70. Where the first fastening components 82 comprise loopfasteners disposed on the inner surface 28 and the second fasteningcomponents 84 comprise hook fasteners disposed on the outer surface 30,the first fastening components can be sized larger than the secondfastening components to ensure coverage of the rigid, outwardly-directedhooks.

[0098] The fastening components 84, 82 can be adhered to the respectiveside panels 34, 134 by any means known to those skilled in the art suchas adhesive bonds, ultrasonic bonds or thermal bonds. The fasteningcomponents 82, 84 may comprise separate fastening elements or distinctregions of an integral material. For example, the training pants 20 caninclude an integral second fastening material disposed in the frontwaist region 22 for refastenably connecting to the first fasteningcomponents 82 at two or more different regions, which define the secondfastening components 84 (FIG. 1). In a particular embodiment, thefastening components 82, 84 can comprise integral portions of the waistregions 24, 22. For instance, one of the elastomeric front or back sidepanels 34, 134 can function as second fastening components 84 in thatthey can comprise a material which is releasably engageable withfastening components 82 disposed in the opposite waist region.

[0099] The fastening components 82, 84 of the illustrated embodimentsare rectangular, although they may alternatively be square, round, oval,curved or otherwise non-rectangularly shaped. In particular embodiments,each of the fastening components 82, 84 has a length aligned generallyparallel to the longitudinal axis 48 of the training pants 20 and awidth aligned generally parallel to the transverse axis 49 of thetraining pants. For a child of about 9 to about 15 kilograms (20-30pounds), for example, the length of the fastening components 82, 84 isdesirably from about 5 to about 13 centimeters, such as about 10centimeters, and the width is desirably from about 0.5 to about 3centimeters, such as about 1 centimeter. With particular embodiments,the fastening components 82, 84 can have a length-to-width ratio ofabout 2 or greater, such as about 2 to about 25, and more particularlyabout 5 or greater, such as about 5 to about 8. For other embodimentssuch as for adult products, it may be desirable for one or more of thefastening components to comprise a plurality of relatively smallerfastening elements. In that case, a fastening component or individualfastening elements may have an even smaller length-to-width ratio, forexample, of about 2 or less, and even about 1 or less.

[0100] As shown in FIG. 1, when the fastening components 82, 84 arereleasably connected, the side edges 36 of the absorbent chassis 32 inthe crotch region 26 define the leg openings 52, and the waist edges 38and 39 of the absorbent chassis, including the waist end edges 72 of theside panels 34, 134, define the waist opening 50. For improved formationof the leg openings 52, it can be desirable in some embodiments for thefront side panels 34 to be longitudinally spaced from the back sidepanels 134 as shown in FIGS. 2 and 3. For example, the front side panels34 can be longitudinally spaced from the back side panels 134 by adistance equal to about 20 percent or greater, particularly from about20 to about 60 percent, and more particularly from about 35 to about 50percent, of the overall length of the pants 20.

[0101] When connected, the fastening components 82, 84 of theillustrated embodiment define refastenable engagement seams 88 (FIG. 1)which desirably although not necessarily extend substantially the entiredistance between the waist opening 50 and the leg openings 52. Morespecifically, the engagement seams 88 can cover about 80 to 100 percent,and particularly about 90 to about 98 percent, of the distance betweenthe waist opening 50 and each leg opening 52, which distance is measuredparallel to the longitudinal axis 48. To construct the engagement seams88 to extend substantially the entire distance between the waist and legopenings 50 and 52, the fastening components 82, 84 can be formed tocover about 80 to 100 percent, and more particularly about 90 to about98 percent, of the distance between the waist end edge 70 and the legend edge 72 of the side panels 34, 134. In other embodiments, thefastening components can comprise a plurality of smaller fasteningelements covering a smaller portion of the distance between the waistopening 50 and the leg openings 52, for example, about 20 to about 70percent, but spaced apart to span a larger percentage of the distancebetween the waist opening and the leg openings.

[0102] For the engagement seams 88 to be located at the sides of thewearer, it can be particularly desirable for the transverse distancebetween the fastening components 82 of the back side panels 134 to besubstantially equal to the transverse distance between the fasteningcomponents 84 of the front side panel 134. The transverse distancebetween a set of fastening components 82, 84 is measured parallel to thetransverse axis 49 between the longitudinal center lines of thefastening component, measured with the side panels 34, 134 in anunstretched condition. Alternatively, fasteners do not need to beparallel to the transverse axis 49 of the pant.

[0103] FIGS. 4-6 generally illustrate apparatus of the present inventionfor making a pre-fastened article, and more particularly for making thepre-fastened, refastenable training pants 20 shown in FIG. 1. Theapparatus comprises an assembly section, generally indicated at 100 inFIG. 4, for making partially assembled training pants 102 in an unfoldedconfiguration, a folding section, generally indicated at 200 in FIG. 5,for folding the partially assembled pants generally at the crotch region26, and a seaming section, generally indicated at 250 in FIG. 6, forconnecting the fastening components 84, 82 of the respective front andback side panels 34, 134 to form the pre-fastened training pants.

[0104] The various elements of the training pants 102 can be connectedtogether in the assembly section 100 by any means known to those skilledin the art such as, for example, adhesive, thermal and/or ultrasonicbonds. Desirably, most of the elements are connected using ultrasonicbonding for improved manufacturing efficiency and reduced raw materialcosts. Certain garment manufacturing equipment which is readily knownand understood in the art, including frames and mounting structures,ultrasonic and adhesive bonding devices, transport conveyors, transferrolls, guide rolls, tension rolls, and the like, have not been shown inFIGS. 4 and 5. Suitable absorbent supply mechanisms, web unwinds,conveyor systems, registration systems, drive systems, control systemsand the like, for use with the present apparatus are disclosed in U.S.Pat. No. 5,766,389 issued Jun. 16, 1998 to Brandon et al., the entiredisclosure of which is incorporated herein by reference. Also, the outercover graphics 61 are not shown in FIGS. 4-7.

[0105] With particular reference to the assembly section 100 shown inFIG. 4, a continuous supply of material 104 used to form the bodysideliner 42 is provided from a supply source 106. The supply source 106 cancomprise for example any standard unwind mechanism, which generallyincludes a pair of spindles, a festoon assembly, and a dancer roll forproviding bodyside liner material 104 at a desired speed and tension.

[0106] Various elements can be disposed on and/or bonded to the bodysideliner material 104 as the material travels in a machine directionidentified by arrow 108. In particular, a surge layer can be provided atan application station 110 and disposed on and/or bonded to the bodysideliner material 104. The surge layer can comprise either a continuous webor discrete sheets. Additionally, a containment flap module 112 can beprovided downstream from the supply source 106 for attachingpre-assembled containment flaps to the bodyside liner material 104. Asvarious elements are added in the assembly section 100, a continuouslymoving product assemblage 113 is formed. The product assemblage 113 willbe cut downstream to form the partially assembled, discrete trainingpants 102.

[0107] A plurality of absorbent assemblies 114 can be provided from asuitable supply source 115. The supply source 115 can be anyconventional mechanism for supplying the absorbent assemblies 114.Generally, a conventional supply source can include a hammermill forforming fluff fibers and, if desired, for providing an enclosure formixing superabsorbent material with the fluff fibers, and thendepositing the fluff and superabsorbent material on a forming drumhaving a desired absorbent design. The individual absorbent assemblies114 can be disposed intermittently on the continuously moving bodysideliner material 104, one for each pair of training pants. The position ofthe absorbent assemblies 114 can be registered with the position of thesurge material, if employed. The absorbent assemblies 114 can be bondedto one or more other components using adhesives or other suitable means.Alternatively, composite absorbent materials can be fed into theconverting process from rolls or compressed packages, such as festoonedbales.

[0108] Continuous webs of material 116 used to form the side panels 34,134 can be provided from suitable supply sources 117. The supply sources117 can comprise one or more standard unwind mechanisms. The side panelmaterial 116 can be cut into individual strips 118 and positionedpartially on the bodyside liner material 104 using an applicator device120. In the cross machine direction, the individual strips 118 desirablyextend laterally outward from the bodyside liner material 104 (see FIGS.4 and 7) and overlap the bodyside liner material by an amount such asabout 2 or more centimeters to permit bonding of the strips to thebodyside liner and/or the containment flap material. In the machinedirection 108, the position of the strips 118 can be registered relativeto the absorbent assemblies 114 so that the product assemblage 113 canbe cut between the absorbent assemblies with each strip 118 of sidepanel material 116 forming both a front side panel 34 and a back sidepanel 134 of consecutive pants 102.

[0109] One suitable applicator device 120 is disclosed in U.S. Pat. Nos.5,104,116 issued Apr. 14, 1992 and 5,224,405 issued Jul. 6, 1993 both toPohjola, which are incorporated herein by reference. The applicatordevice 120 can comprise a cutting assembly 122 and a rotatable transferroll 124. The cutting assembly 122 employs a rotatable knife roll 126and a rotatable vacuum anvil roll 128 to cut individual strips 118 fromthe continuous side panel material 116. The strips 118 cut by a blade onthe knife roll 126 can be maintained on the anvil roll 128 by vacuum andtransferred to the transfer roll 124.

[0110] The rotatable transfer roll 124 can comprise a plurality ofrotatable vacuum pucks 130. The vacuum pucks 130 receive the strips 118of material 116 from the cutting assembly 122 and rotate and transferthe strips to the continuously moving bodyside liner material 104. Whenthe strips 118 are positioned as desired relative to the bodyside linermaterial 104, the strips are released from the pucks 130 byextinguishing the vacuum in the pucks. The pucks 130 can continue torotate toward the cutting assembly 122 to receive other strips. Asdisclosed by Van Gompel et al., the material 116 used to form the sidepanels can alternatively be provided in continuous form and pressurizedfluid-jets or a rotary die cutter can be employed to cut the material toform leg openings 52. Still alternatively, the side panels 34, 134 ofthe training pants 20 can be provided by portions of the bodyside liner42 and/or outer cover 40.

[0111] A continuous supply of material 140 used to form the outer cover40 can be provided from a supply roll 142 or other suitable source. Theouter cover material 140 can be transported over a laminator roll 144and bonded to the bodyside liner material 104. The absorbent assemblies114 are thereby sandwiched between the continuous materials 104 and 140.The inward portions of the strips 118 of side panel material 116 canalso be disposed between the bodyside liner material 104 and the outercover material 140. Alternative configurations for attaching the sidepanel material 116 are disclosed by Van Gompel et al. Various elementssuch as leg elastics 58 or waist elastics 54 and 56 can be bonded to theouter cover material 140 at an application station 146 prior to unitingthe bodyside liner and outer cover materials 104 and 140. Alternatively,leg elastics or waist elastics can be initially bonded to the bodysideliner material 104 or another material.

[0112] Bonding devices 148 such as ultrasonic bonders can be employeddownstream from the laminator roll 144 to bond the bodyside linermaterial 104, side panel material 116 and outer cover material 140. Forexample, these materials can be transported between a rotary ultrasonichorn and an anvil roll. Suitable rotary ultrasonic horns are describedin U.S. Pat. No. 5,110,403 to Ehlert, which is incorporated herein byreference. Such rotary ultrasonic horns generally have a diameter offrom about 5 to about 20 centimeters and a width of from about 2 toabout 15 centimeters. Alternatively, the ultrasonic horn may be astationary ultrasonic horn as is also known to those skilled in the art.Other suitable ultrasonic horns and ultrasonic bonders are commerciallyavailable from Branson Sonic Power Company, Danbury, Conn., U.S.A. Thebonding devices 148 could otherwise be a thermal or adhesive bonder asare well known.

[0113] The continuously moving product assemblage 113 next advances to afastener application station 150 where fastening components 82, 84 arebonded to the strips 118 of side panel material 116. The location of thefastening components 82, 84 on the composite is a function in part ofthe configuration of the assembly section 100. As shown in FIG. 4, theassembly section 100 of the illustrated embodiment is configured so thatthe upward facing surface of the product assemblage 113 will become theouter surface 30 of the training pants 20 and the downward facingsurface will become the inner surface 28. Moreover, the illustratedassembly section 100 is configured to produce partially assembledtraining pants 102 having the front waist region 22 of a leading garmentconnected to the back waist region 24 of a trailing garment. However, itis understood that the assembly section 100 could alternatively employany combination of different orientations. For example, the upwardfacing surface of the product assemblage 113 could form the innersurface 28 of the finished pants 20. Additionally or alternatively, theback waist region 24 of a leading pair of pants 102 can be connected tothe front waist region 22 of the trailing pair of pants, or the pantscan be arranged in a front-to-front/back-to-back relationship. Stillalternatively, the assembly section 100 could be constructed as across-machine direction process wherein the longitudinal axis 48 of eachpair of partially assembled pants 102 could be perpendicular to themachine direction 108 during part or all of the assembly process.

[0114] The locations of the fastening components 82, 84 in thisembodiment are best illustrated in FIG. 7, which shows a portion of theproduct assemblage 113 moving in the direction of arrow 108 immediatelyfollowing the fastener application station 150. Each individual strip118 of side panel material 116 defines a leading edge 152, a trailingedge 154, a distal edge 156 and an interior edge 158. A dashed line 159illustrates the location at which the product assemblage 113 cansubsequently be cut to provide the discrete partially assembled trainingpants 102. Based on the illustrated orientation of the continuouslymoving product assemblage 113, the first fastening components 82 can bebonded to the underside of the strips 118 and the second fasteningcomponents 84 can be bonded to the top of the strips. Additionally, thefirst fastening components 82 can be disposed relatively closer to thetrailing edge 154 and the second fastening components 84 can be disposedrelatively closer to the leading edge 152. The first fasteningcomponents 82 can be spaced in the machine direction 108 from the secondfastening components 84 so that the cut line 159 passes therebetween.

[0115] With reference again to FIG. 4, continuous webs of a secondfastener material 160 used to form the second fastening components 84can be provided from supply rolls 162 or other suitable sources. Thesecond fastener materials 160 can be cut into individual secondfasteners 84 by cutting assemblies 164 or other suitable devices. Theillustrated cutting assemblies 164 include rotatable knife rolls 166,rotatable vacuum anvil rolls 167, and rotatable backing rolls 168. Thecontinuous second fastener materials 160 can be cut by blades on theknife rolls 166, maintained on the anvil rolls 167 by vacuum, anddisposed on the top surfaces of the strips 118 of side panel material116.

[0116] Similarly, continuous webs of first fastener material 170 used toform the first fastening components 82 can be provided from supply rolls172 or other suitable sources. The first fastener materials 170 can becut into individual first fastening components 82 by cutting assemblies174 or other suitable devices. The illustrated cutting assemblies 174include rotatable knife rolls 176, rotatable vacuum anvil rolls 177, androtatable backing rolls 178. The continuous first fastener materials 170can be cut by blades on the knife rolls 176, maintained on the anvilrolls 177 by vacuum, and disposed on the undersides of the strips 118 ofside panel material 116.

[0117] It is contemplated that other arrangements can be used to attachthe fastening components 82, 84 to the side panel material 116. Forexample, the fastening components 82, 84 can be applied to the sidepanel material 116 prior to uniting the side panel material with thebodyside liner material 104 and/or the outer cover material 140; thefastening components can be applied to the bodyside liner material 104and/or outer cover material 140, whether separate side panels 34, 134are used or not; portions of other elements such as the bodyside linerand/or outer cover can form one or more of the fastening components; theseparate side panels or integral side panels can themselves form one ormore of the fastening components; the fastening components 82, 84 can beattached as pre-engaged composites or the like without departing fromthe scope of this invention.

[0118] After the fastening components 82, 84 are disposed on the strips118 of side panel material 116, bonding devices 180 such as ultrasonicbonders can be employed to bond the fastening components to the strips.For example, the strips 118 can be transported between a rotaryultrasonic horn and an anvil roll, which devices are positioned on eachside of the process at the cross machine direction location of thefastening components 82, 84. Particular ultrasonic bond patternscomprising individual, circular bonds which are compatible withmechanical fastening materials are disclosed in U.S. Pat. No. 5,660,666issued Aug. 26, 1997 to Dilnik et al., which is incorporated herein byreference. Efficient arrangements for attaching the fastening componentswith nonadhesive bonding devices are further described in U.S. patentapplication Ser. No. 09/855484, filed on May 15, 2001 by J. D. Coenen etal. and titled “Methods For Making Garments With Fastening Components,”which is incorporated herein by reference. For secure attachment, it maybe desirable to attach the fastening components 82, 84 to the side panelmaterial 116 with both adhesive and thermal bonds. Suitable attachmentadhesives are available from commercial vendors such as FindleyAdhesive, Inc., Wauwatosa, Wis., U.S.A.

[0119] In particular embodiments, the bonding devices 180 can providetimed, non-uniform bonding of the fastening components to the side panelmaterial 116. The degree of bonding, such as the number of bonds perunit area or the bond strength per unit area, can be greater in certaintarget areas compared to non-target areas. Enhanced bonding in targetareas can be beneficial particularly near the waist and leg openings 50and 52 to reduce delamination of the fastening components from the sidepanel material 116. Thus, the bonding devices 180 can be adapted tocreate relatively more bonds or stronger bonds between the fasteningcomponents 82, 84 and the side panel material 116 when the side panelmaterial 116 reaches a particular machine direction 108 location. In oneparticular embodiment, the target areas correspond to portions of thefastening components 82, 84 near the waist edges 38 and 39. The bondingdevices 180 can be registered to provide a relatively higher degree ofbonding which begins while disposed on one fastening component (such asthe fastening component 84 in FIG. 7), continues through the regionwhere the product assemblage 113 will subsequently be cut (see cut line159 in FIG. 7), and ends after being disposed on another fasteningcomponent (such as fastening component 82). Alternatively, the bondingdevices 180 can destroy engaging elements of the fastening components82, 84 in the target areas, so that the fastening components will beless able to aggressively attach to one another in the target areas.

[0120] The strips 118 of side panel material 116 can be trimmed ifdesired, for example to provide angled and/or curved leg end edges 70 inthe back waist region 24 (FIGS. 2 and 3). To this end, the assemblysection 100 can include a die cutting roll 182 and a backing roll 184.In the illustrated embodiment, a portion of each strip 118 is trimmedfrom the trailing edge 154 (FIG. 7) in order to form the angled and/orcurved leg end edges 70 in the back waist region 24.

[0121] The method and apparatus to this point provides a continuous webof interconnected and partially assembled training pants moving in themachine direction indicated by arrow 108. This continuously movingproduct assemblage 113 is passed through a cutter 186 which selectivelycuts the web into discrete, partially assembled training pants 102. Suchcutters 186 are generally known to those skilled in the art and caninclude, for example, the combination of a cutting roll 187 and an anvilroll 188 through which the web travels. The anvil roll 188 can include ahardened steel rotating roll while the cutting roll 187 can include oneor more flexible hardened steel blades clamped onto another rotatingroll. The pinching force between the blade on the cutting roll 187 andthe anvil roll 188 creates the cut. The cutting roll 187 can have one ormore blades depending upon the desired distance between the cuts. Thecutter 186 can further be configured to provide a spacing between theindividual cut pieces after they are cut. Such a spacing can be providedby transferring the cut pieces away from the cutter at a higher speedthan the speed at which the web is provided to the cutter.

[0122] With particular reference now to FIGS. 5, 8 and 9, the discretepartially assembled training pants 102 are delivered to and folded atthe folding section 200 using any suitable folding mechanism 202. Forexample, the training pants 102 can be folded about a fold line whichgenerally bisects the training pants laterally through the crotch region26. As such, the waist regions 22 and 24 of the partially assembledpants 102 are positioned in opposed relationship with each other, withthe side panels 34, 134 extending laterally outward therefrom parallelto the transverse axis 49 of the training pants in opposed relationshipwith each other. Desirably, each of the training pants 102 isconsistently folded about the fold line such that the front and backwaist edges 38 and 39 of the training pants align with each other.

[0123] A variety of folding mechanisms 202 can be used, such as bladefolders, linear folders, book folders, tucker blades or the like. Thespecific type selected for a given application may depend upon the typeof garment being manufactured and the type of fastening mechanism usedto secure the garment in a pants configuration. In the illustratedembodiment, the folding mechanism 202 controls the side panels 34, 134during folding so that the refastenable fastening components 82, 84 areinhibited against engaging one another or engaging another materialduring the folding operation. Other arrangements for maintainingseparation of the side panels 34, 134 and fastening components 82, 84during folding are disclosed in U.S. patent application Ser. No.09/855981, filed on May 15, 2001 by J. D. Coenen et al. and titled“Folding And Manufacture Of Pants,” which is incorporated herein byreference.

[0124] The illustrated blade folding mechanism 202 comprises a pluralityof rotating folding or tucker blades 240 (FIG. 9) which are configuredto contact the training pants 102 along the fold line. Rotation of thefolding blades 240 can force the training pants 102 into a nip 204between two rotating folding conveyors 206 and 208 causing the trainingpants to fold about the fold line. The folding conveyors 206 and 208 canform part of a transport system for moving the folded training pants 102in the machine direction 108 (FIG. 8). The folded training pants 102 areillustrated as being transported in the machine direction 108 with thecrotch region 26 leading the waist regions 22 and 24. Alternatively, theprocess and apparatus could be modified so that the waist regions leadthe crotch region (not shown).

[0125] The series of unfolded, discrete training pants 102 can betransferred from the vacuum anvil roll 188 (FIG. 4) of the cutter 186 tothe upper folding conveyor 206 (FIGS. 5, 8 and 9). The training pants102 can be held by vacuum on the upper folding conveyor 206 andtransported toward the nip 204 formed between the folding conveyors 206and 208. While being transported toward the nip 204, the side panels 34,134 can be smoothed out or straightened if desired by various meansincluding fluid stabilizing devices. For example, air knives 215 (FIG.8), air bars, air nozzles or the like can be mounted in proximity to theupper folding conveyor to provide a stream of fluid directed toward theside panels to stabilize and/or straighten the side panels. The airknives 215 can blow the side panels 34, 134 against skid plates 216positioned transversely outward from the upper folding conveyor belt212. Alternatively, or in addition thereto, the upper folding conveyor206 can incorporate fluid stabilizing devices (not shown) consisting offluid manifolds operatively connected to a high pressure fluid source tofluidly shake the side panels 34, 134. The fluid stabilizing devices(not shown) desirably prevent folding of the side panels 34, 134 as thetraining pants 102 move along the upper folding conveyor 206. Sensingdevices can also be employed at this point to detect products that havefolded side panels or that are misaligned relative to the machine centerline.

[0126] The product folding nip 204 can be formed between a timed vacuumnose roll 218 of the upper folding conveyor 206 and a timed vacuum noseroll 219 of the lower folding conveyor 208 (FIGS. 5 and 8). As theleading edge of each pair of pants 102 is introduced onto the upper noseroll 218, a rotary valve can be used to negate vacuum draw of the noseroll. This allows the leading edge of the pants 102 to pass by the noseroll 218 without getting sucked into the nip 204. Alternatively ofcourse, the vacuum source can be temporarily disconnected from the noseroll 218. Any suitable control system can be used to repeatedly activateand deactivate vacuum operation of the nose rolls 218 and 219. Inparticular embodiments, compressed air nozzles (not shown) can beemployed to cycle vacuum to the nose rolls 218 and 219. This can be doneby injecting compressed air inside the internal chambers of nose rolls218 and 219 to negate the vacuum.

[0127] A product control drum 220 can guide the leading half of thetraining pants 102 onto a transfer plate 222 (FIGS. 5 and 8). Theproduct control drum 220 can comprise a plurality of vacuum pucks 224which rotate in the direction of arrow 225. The illustrated productcontrol drum 220 includes four vacuum pucks 224 to guide four trainingpants 102 per revolution. Rotation of the product control drum 220 canbe timed so that a vacuum puck 224 grabs the leading half of a trainingpants 102 and transfers the,leading edge onto the transfer plate 222.The absorbent chassis 32 and/or side panels 134 of the leading half canbe carried on a vacuum puck 224 past the nose roll 219 of the lowerfolding conveyor 208. Compressed air can be introduced inside this lowernose roll 219 at this point to negate vacuum draw and to permit theentire leading edge and side panels 134 to transfer onto the transferplate 222. Alternatively of course, the vacuum source can be temporarilydisconnected from the nose roll 219.

[0128] With reference to FIG. 9, the opposed tucker blades 240 move inan orbital manner to pass through the vertical path of the trainingpants 102. The tucker blades 240 can contact the crotch region 26 of thepants 102 and insert the crotch region into the folding nip 204. As thishappens, the leading half of the pants 102 reverses direction over thetransfer plate 222 and is pulled into the nip 204. The vacuum puck 224can cease drawing vacuum at this point to release the leading half.Correspondingly, the trailing half of the pants 102 is pulled around theupper nose roll 218. Thus, both halves of the training pants 102 canchange from motion in a generally vertical plane to motion between thefolding conveyors 206 and 208 in a generally horizontal plane.

[0129] The illustrated folding mechanism 202 can maintain separationbetween the front and back side panels 34, 134. As the pants 102 enterthe folding nip 204, compressed air can be shut off to the upper noseroll 218 so that the side panels 34 of the trailing half are drawn byvacuum to the upper nose roll. The trailing side panels 34 are thusdrawn to the upper nose roll 218 and follow its rotation around the rolland over side panel separation plates 230 (FIGS. 8 and 10). Similarly,as the leading half of the pants 102 is pulled into the folding nip 204,compressed air can be shut off to the lower nose roll 219 so that theside panels 134 of the leading half are drawn by vacuum to the lowernose roll. The leading side panels 134 are thus drawn to the lower noseroll 219 and follow its rotation around the roll and beneath the sidepanel separation plates 230.

[0130]FIG. 10 illustrates a portion of partially assembled trainingpants 102 positioned between the upper and lower folding conveyors 206and 208 at a location downstream from the nose rolls 218 and 219. Atthis point, the training pants 102 have been folded in half andtransported in the machine direction 108 (FIG. 8) by the conveyors 206and 208. The illustrated folding mechanism 202 can thus maintain thefront side panels 34 separated from the back side panels 134 duringfolding.

[0131] Each folding conveyor 206 and 208 as illustrated in greaterdetail in FIG. 10 can comprise a frame structure 210, a plurality ofrotatable pulleys 211 associated with the frame structure, and acontinuous belt 212 carried on the pulleys. A drive system and conveyorshaft (not shown) can be used to rotatively drive one or more of thepulleys. The folding conveyors 206 and 208 can comprise vacuum conveyorsas are well known in the art, in which case the continuous belt can beformed of a fluid permeable material. The folding conveyors desirablytransport the training pants 102 with the longitudinal center line ofthe pants traveling on the longitudinal center line of the conveyors. Asdepicted, the front and back side panels 34, 134 can project laterallyoutward from the frame structure 210, outstretched in the cross-machinedirection.

[0132] While traveling on the folding conveyors 206 and 208, the sidepanels 34, 134 can be smoothed out or straightened if desired by variousmeans including fluid stabilizing devices (not shown). It is possible,if desired, to provide fluid streams such as from air bars 215 to guidethe side panels 34, 134 outward from the upper folding conveyor 206,upstream of the folding nip 204. In addition, it is possible, ifdesired, to provide fluid streams such as from air bars 217 to continueguiding and controlling the side panels 134 of the leading half of theproduct 102, while over the transfer plate 222 downstream of the foldingnip 204. The air bars 215 and 217 can be located adjacent the outboardedges of conveyors 206 and 208, directing air generally toward the sidepanels 34, 134 of training pant 102 and generally away from the edges ofthe conveyors. The air bars 215 and 217 can additionally be displacedfrom the planes of the conveyors 206, 208 so that the training pant 102can pass between the air bars and the conveyors. Suitable fluidstabilizing devices can comprise air knives, air bars, air nozzles,vacuum devices or the like to provide a stream of fluid directed towardthe side panels. The fluid stabilizing devices can be incorporatedwithin either or both of the folding conveyors 206 and 208 or cancomprise separate devices positioned in proximity to the conveyors.

[0133] Following conveyance of the partially assembled training pants102 through the illustrated folding mechanism 202, the front waistregion 22 and front side panels 34 of the partially assembled trainingpants as shown in FIG. 10 are disposed above the back waist region 24and back side panels 134. The fastening components 82 are disposed onthe inner surface 28 of the back side panels 134 and the fasteningcomponents 84 are disposed on the outer surface 30 of the front sidepanels 34. The separation plates 230 can extend in the machine direction108 to maintain separation between the front and back side panels 34,134. The separation plates 230 can comprise a low friction material orcoating, such as: stainless steel; Teflon®; aluminum; ultra-highmolecular weight polyethylene (UHMW-PE); polyoxymethylene (acetals), forinstance a homopolymer available from E. I. Du Pont de Nemours andCompany, Wilmington, Del., USA under the tradename DELRIN; or the like.In particular embodiments, the separation plates 230 can comprise a thinlayer of Teflon®, UHMW-PE, DELRIN or the like glued to a plate formed ofsteel, aluminum or the like. The separation plates 230 can be mountedusing suitable support members 232 (FIG. 10) to either the foldingconveyors 206 or 208 or other suitable frame structure (not shown).Alternatively, the side panel separation plates 230 can have airstabilization as a component.

[0134] From the folding station 200, the continuous stream of discrete,partially assembled and folded training pants 102 enters a seamingsection 250 (FIG. 6) and is transported therethrough in a machinedirection 108 indicated by the direction arrow in FIG. 6. In general,the seaming section 250 controls the unattached side panels 34, 134 soas to position portions of the side panels, and more particularly therespective fastening components 84, 82 of the side panels, in at leastpartially opposed relationship with each other; to connect the fasteningcomponents together to define the engagement seams 88; and to then pinchor compress the side panels together at the engagement seam and inspectthe pinched or compressed engagement seams 88 to assess whether the sidepanels are properly aligned and connected. The seaming section 250 thusconverts the discrete, partially assembled and folded training pants 102into the pre-fastened training pants 20 (FIG. 1) having the waistopening 50, leg openings 52 and the interior space 51 bounded in part bythe engagement seams 88.

[0135] Construction and operation of the seaming section 250 is furtherdescribed herein with particular reference to FIG. 11. FIG. 11illustrates a side elevation of the upstream portion of the seamingsection 250. FIGS. 12-16 are sections taken at sequential locationsalong the seaming section 250. For ease of explanation, these sectionsillustrate only one side (e.g., the right hand side relative to themachine direction 108) of the seaming section 250 and the training pants102 conveyed therethrough, it being understood that the left hand sideof the seaming section is constructed and operates substantially similarto the right hand side.

[0136] With particular reference to FIGS. 6, 11 and 12, the seamingsection 250 comprises upper and lower alignment conveyors, generallyindicated as 256 and 258, respectively, which broadly define a transportsystem for transporting discrete, partially assembled training pants 102from the upper and lower folding conveyors 206 and 208 (FIG. 5) throughthe seaming section in the machine direction 108. More specifically, thealignment conveyors 256 and 258 define therebetween a pant transportplane, which in the illustrated embodiment is generally horizontal, inwhich the training pants 102 are transported through the seaming section250. As illustrated, the upper alignment conveyor 256 comprises framestructure 260, one or more vacuum chambers 262 (FIG. 12) defined withinthe frame structure, one or more vacuum cover plates 264 (FIG. 12)mounted on the frame structure and one or more continuousfluid-permeable belts 266 carried on a plurality of rotatable pulleys268 or other suitable devices. Similarly, the lower alignment conveyor258 comprises frame structure 270, a vacuum chamber 272 (FIG. 12)defined within the frame structure, a vacuum cover plate 274 (FIG. 12)mounted on the frame structure and a continuous fluid-permeable belt 276carried on a plurality of rotatable pulleys 278 or other suitabledevices. The vacuum cover plates 264 and 274 and related equipment canbe adjustable if desired to accommodate various pants sizes. A drivesystem (not shown) and conveyor shaft (not shown) can be used torotatively drive one or more of the pulleys 268 and 278. The vacuumchambers 262 and 272 can be operatively connected to a source of vacuum(not shown) and the vacuum cover plates 264 and 274 can be provided witha plurality of holes 269 and 279, respectively.

[0137] With reference to FIG. 12, the seaming section 250 is alsoillustrated and described herein with the training pants 102 orientedsuch that the front waist region 22 is drawn against the upper alignmentconveyor 256 and the back waist region 24 is drawn against the loweralignment conveyor 258. Thus, the front side panels 34 are initiallypositioned above the back side panels 134, with the fastening component84 of the front side panel facing up (e.g., away from the fasteningcomponent 82 of the back side panel). However, it is understood that thepants 102 may be inverted, e.g., such that the back waist region 24 isdrawn against the upper alignment conveyor 256 while passing through theseaming section 250, without departing from the scope of this invention.Also, while the seaming section 250 of the illustrated embodimentassembles pre-fastened training pants 20 with the back side panel 134overlapping the front side panel 34 as shown in FIG. 1, it is understoodthat the seaming section 250 could be configured so that the front sidepanel overlaps the back side panel after passing through the seamingsection.

[0138] The upper alignment conveyor 256 of the illustrated embodimenthas an operative width sufficient to draw the full width of the frontwaist region 22 and front side panels 34 of the training pants 102against the upper conveyor belt 266 as shown in FIG. 12 fully orpartially along the length of the seaming section 250. The loweralignment conveyor 258 is relatively narrow compared to the upperalignment conveyor 256 and has a width, for example, approximately equalto the width of the absorbent chassis 32, and more particularly the backwaist region 24 thereof. This permits the back side panels 134 to extendlaterally out beyond the lower alignment conveyor 258. As anotherexample, the width of the lower alignment conveyor 258 may generallycorrespond to the distance between the seams 66 (FIG. 2) along which theside panels 34 and 134 are bonded to the absorbent chassis 32.

[0139] The respective vacuum pressures acting on the upper and loweralignment conveyors 256, 258 are preferably sufficient to draw andretain the waist regions 22 and 24 of the training pants 102 against therespective conveyors to inhibit pinching of the waist regions betweenthe conveyors. Vacuum control of the waist regions 22, 24 also inhibitslateral movement of the absorbent chassis 32 to thereby improvepositioning and alignment of the side panels 34, 134. As an example, theupper alignment conveyor 256 can operate over a range of vacuumpressures, such as about one to about 30 inches of water belowatmospheric pressure. The lower alignment conveyor 258 can also operateover a range of vacuum pressures, such as in the range of about one toabout 30 inches of water or greater below atmospheric pressure. Suitableconveyor mechanisms such as vacuum conveyors or non-vacuum conveyors areknown in the art and available from various commercial vendors and thuswill not be further described herein except to the extent necessary toset forth the present invention.

[0140] Referring to FIGS. 6 and 11, the seaming section 250 furthercomprises side panel positioning devices, generally indicated at 330,for vertically and laterally positioning the back side panels 134relative to the front side panels 34; and side panel transfer devices,generally indicated at 430, for moving the respective fasteningcomponents 84, 82 of the side panels 34, 134 into engagement with eachother to define the engagement seams 88.

[0141] The positioning devices 330 of the illustrated embodiment aremounted on opposite sides of the lower alignment conveyor 258, althoughit is understood that the positioning devices may instead be mounted onthe upper alignment conveyor 256 or other suitable frame structure ofthe seaming section 250. Each positioning device 330 comprises anelongate tubular member 332 extending generally in the machine direction108 from an upstream end (FIGS. 6, 11) 334 adjacent an upstream end ofthe seaming section 250 to a downstream end 336. The tubular member 332of the illustrated embodiment comprises opposed walls 344, 346 (FIG. 12)together defining a generally L-shaped cross-section of the tubularmember and an internal flow chamber 340 extending longitudinallytherethrough. A slot 342 (FIG. 12) is formed in the tubular member 342in fluid communication with the internal flow chamber 340 and extendslongitudinally substantially the length of the tubular member. The slot342 faces laterally inward toward the lower alignment conveyor 258 forreceiving the back side panel 134 into the internal flow chamber 340(FIG. 12). The walls 344, 346 of the tubular member 332 may be formedseparately and secured together by suitable methods, or they may beformed integrally. It is also understood that the tubular member 332 andinternal flow chamber 340 may be other than L-shaped in cross-sectionwithout departing from the scope of this invention.

[0142] The tubular member 332 can be formed of any suitable material.For example, portions or surfaces of the tubular member 332 which maycome into contact with the training pants 102 are desirably formed of alow friction material. Suitable low friction materials or coatingsinclude but are not limited to: stainless steel; low carbon steel;polycarbonate material; Teflon®; aluminum; ultra-high molecular weightpolyethylene (UHMW-PE); polyoxymethylene (acetals), for instance ahomopolymer available from E. I. Du Pont de Nemours and Company,Wilmington, Del. USA under the tradename DELRIN; or the like.

[0143] The flow chamber 340 of the tubular member 332 is in fluidcommunication with a source of vacuum V via suitable vacuum hoses 350(FIGS. 6, 11) for drawing fluid, such as air, into the flow chamber viathe slot 342 formed in the tubular member such that the fluid flowsgenerally laterally outward within the flow chamber as indicated by thedirection arrow in FIG. 12. The vacuum pressure within the flow chamber340 can vary, for example, from about 1 to about 10 inches of water orgreater below atmospheric pressure, and more particularly from about 2to about 8 inches of water below atmospheric pressure. It is alsocontemplated that instead of or in addition to the vacuum pressure,pressurized fluid (not shown) can be directed into the internal chamber340 via the slot 342 to establish the fluid flow laterally outwardwithin the internal chamber.

[0144] The fluid flow within the internal flow chamber 340 is sufficientto draw the back side panel 134 laterally outward relative to themachine center line, and desirably at least partially into the flowchamber, to thereby promote straightening of the back side panel. Theslot 342 and the flow chamber 340 are thus desirably sized toaccommodate the back side panel 134 and fluid flow therethrough. Forexample, the slot 342 desirably has a width of about 5 millimeters toabout 20 millimeters, and more desirably about 10 millimeters to about15 millimeters. The walls 344, 346 of the tubular member 332 canconverge or diverge relative to one another, or be generally parallel asillustrated. The depth of the flow chamber 340 generally depends uponthe application and the amount of back side panel 134 material to bereceived therein. For example, the internal flow chamber 340 may have adepth of about 10 to about 20 centimeters. As seen best in FIGS. 12 and13, the slot 342 of the tubular member 332 of each positioning device330 is positioned lower than the lower alignment conveyor 258 so thatwhen the back side panel 134 is drawn into the flow chamber 340, theback side panel extends laterally outward and down from the back waistregion 24 being held against the conveyor belt.

[0145] Now referring to FIGS. 11 and 14-16, the side panel transferdevices 430 (also referred to as scrunch conveyors) comprise vacuumconveyors spaced laterally outward of the lower alignment conveyor 258 adistance generally corresponding to the lateral positions of thefastening components 82 of the back side panels 134 as the panels exitthe downstream end 336 of the positioning devices 330. Moreparticularly, each side panel transfer device/scrunch conveyor 430comprises suitable frame structure 432, rotatable pulleys 434 (FIGS. 6and 11) associated with the frame structure, a vacuum chamber 436 (FIG.14) defined within the frame structure, a vacuum cover plate 438 (FIG.14) mounted on the frame structure, and a continuous belt 440 carried bythe pulleys. A drive mechanism (not shown) and corresponding conveyorshaft (not shown) can be used to rotatively drive one or more of thepulleys 434. The side panel transfer devices/scrunch conveyors 430 canbe aligned parallel to the machine direction or canted inward oroutward, for example, to improve side panel 34, 134 alignment with themachine direction.

[0146] Each side panel transfer device/scrunch conveyor 430 angles uptoward the pants transport plane defined by the upper and loweralignment conveyors 256, 258 as the device extends in the machinedirection 108 from an upstream end 442 disposed slightly upstream andbelow the downstream end 336 of the positioning device 330, to adownstream end 444 disposed in closely spaced relationship with theupper alignment conveyor 256. The side panel transfer device/scrunchconveyor 430 and the upper alignment conveyor 256 thus define a niptherebetween at the downstream end of the device, the purpose of whichwill become apparent.

[0147] The side panel transfer device/scrunch conveyor 430 canalternatively comprise other devices (not shown) for sequentially orsimultaneously affecting upward movement of the laterally outwardportion of the back side panel 134. By way of illustration, suitableside panel transfer devices 430 can alternatively comprise disks orwheels, either aligned in the machine direction 108 or canted and/ortilted relative thereto so that the disks or wheels raise the sidepanels and nip the fasteners together. Suitable wheel devices can, butneed not, be timed elliptical wheels, and can comprise vacuum ortraction surface wheels or the like. Still alternatively, the side paneltransfer devices 430 can comprise 4-bar linkage mechanisms carrying apanel engagement head which contacts the back side panel 134 to raisethe panel relative to the plane of the lower alignment conveyor 258. Therotary motion provided by the 4-bar linkage can allow the panelengagement head to raise a back side panel 134 relative to the loweralignment conveyor 258, with the back side panel being allowed to slipoff the inward edge of the panel engagement head. A drive mechanism forthe 4-bar linkage can be programmed to vary the angular velocity of thepanel-engagement head such that its velocity in the machine direction108 matches the speed of the back side panel 134 while thepanel-engagement head is in contact with the back side panel.Alternatively, the angular velocity of the panel-engagement head can bematched with the velocity of the side panel using a cam gearbox,non-circular gearing, or the like. Such devices could further comprise afeedback system to register the panel-engagement head to the back sidepanel 134. In yet another alternative embodiment, the side paneltransfer devices 430 can comprise folding boards or folding skis toprovide sequential or simultaneous inward and upward relative movementof the laterally outward portions of the back side panels 134 and thefastening components 82.

[0148] In operation, the partially assembled and folded training pants102 are received from the folding section 200 into the upstream end ofthe seaming section 250 generally in the configuration shown in FIG. 10,e.g., with the front waist region 22 of the absorbent chassis 32 foldedover the back waist region 24 and the front and back side panels 34, 134extending laterally out from the front and back waist regions in opposedrelationship with each other. The front side panel 34 is drawn againstthe upper alignment conveyor 256 in an outstretched configuration, withthe fastening component 84 of the front side panel facing up toward theupper alignment conveyor. An outer portion of the back side panel 134 isdrawn through the slot 342 of the positioning device 330 into theinternal flow chamber 340 thereof. At the downstream locationillustrated in FIG. 13, the positioning device 340 has repositioned theback side panel 134 such that the fastening component 82 is laterallynearer the machine centerline. Vacuum is inhibited from drawing alaterally outward portion of the front side panel 34, including thefastening component 84, against the upper alignment conveyor, such as byclosing off laterally outer holes 269 of the vacuum cover plate 264. Asa result, the laterally outward portion of the front side panel 34 tendsto drop, due to gravity, away from the upper alignment conveyor 256 andfolds over a folding finger 267.

[0149] The upper alignment conveyor 256 can alternatively provide auniform or nonuniform vacuum profile in the cross machine direction. Inparticular embodiments, the upper alignment conveyor 256 can draw anonuniform vacuum in the cross-machine direction. Specifically, theupper alignment conveyor 256 can draw a concentrated vacuum at laterallyoutward regions thereof as well as in a central region disposed betweenthe laterally outward regions. The laterally outward regions can bepositioned such that they correspond to locations of the front sidepanels 34 immediately laterally inward from the locations of thefastening components 84. The concentrated vacuum adjacent the insideedge of the fastening components 84 can encourage the inside edgethereof to generally function as a hinge point for folding. Theconcentrated vacuum can be formed by a plurality of slots or an increasein the number of apertures in the vacuum cover plate 264, by separatevacuum chambers, or the like. The focused vacuum in the central regioncan reduce energy consumption and lessen draw of the back side panels134 toward the upper alignment conveyor 256.

[0150]FIG. 14 illustrates the training pants 102 at a locationdownstream of that shown in FIG. 12. The laterally outward portion ofthe front side panel 34 has been folded through approximately 180degrees by a suitable panel folding device (not shown) such that thefastening component 84 of the front side panel is now facing down ingenerally opposed relationship with the fastening component 82 of theback side panel 134. The panel folding device (not shown) acts on thelaterally outward portion of the front side panel 34 after the panel isfolded down over the folding finger 267 and can comprise, for example,one or more air nozzles (not shown) which blow the laterally outwardportion of the front side panel 34, including the initiallyoutward-facing fastening component 84, to a horizontal orientationdirected toward the center line of the upper alignment conveyor 256. Thepanel folding device can operate on a continuous or timed intermittentbasis, and can progressively fold the side panel 34 or fold the sidepanel as a single unit. The panel folding device can alternativelycomprise other mechanisms for creating a suitable force to fold orassist to fold the front side panel 34. For example, the panel foldingdevice can comprise folding boards or skis which fold the front sidepanel through 180 degrees; a helical surface that pushes the front sidepanel into the folded configuration; or the like. Once folded inward,the folded portion of the front side panel 34, including the fasteningcomponent 84, is drawn against the upper alignment conveyor to maintainthe folded configuration of the front side panel.

[0151] Upon reaching the location shown in FIG. 14, the side paneltransfer device/scrunch conveyor 430 is overlapped with the downstreamend 336 of the positioning device 330 such that the portion of the backside panel 134 having the fastening component 82 is supported by theside panel transfer device as the back side panel exits the positioningdevice. At this location, the fastening components 82, 84 are inopposed, vertically spaced relationship with each other. The side paneltransfer device/scrunch conveyor 430 elevates the fastening component 82of the back side panel 134 generally in a “z-direction” perpendicular tothe machine direction 108 while the remaining extent of the back sidepanel hangs generally limp between the lower alignment conveyor 258 andthe transfer device, as shown in FIGS. 15 and 16.

[0152] The connected fastening components 82, 84 are urged together uponpassing between nip 580 (FIG. 11) defined by the downstream end of thetransfer device/scrunch conveyor 430 and the upper alignment conveyor256 to facilitate increased engagement between the fastening componentsas the training pants 102 are conveyed further downstream. The trainingpants 102 are then transported downstream to an inspection station.

[0153] In accordance with the teachings of the present invention, agarment inspection station can be established in the area of the nip580, an adjacent roller 578, the upper alignment conveyor 256 andtransfer device/scrunch conveyor 430. This is a desirable location foran inspection station since the training pants 102 are pinched andcompressed by the conveyors 256, 430 and roller 578 to a minimalthickness in the z-direction which presents an image to an imagecapturing device 600 (FIGS. 17-20), such as a camera, which is as closeto two dimensional as possible thus reducing the possibility of errorsin assessing the position of elements on the training pants 102 thatmight otherwise occur due to separation of the elements in thez-direction. A first example of such an arrangement is schematicallyillustrated in FIG. 17 where an image capturing device 600 in the formof a camera is located beneath an upper reach 602 of the transferdevice/scrunch conveyor 430 and a radiation source 604, such as a lightsource, is disposed above a lower reach 606 of the upper alignmentconveyor 256, adjacent the nip 580 where the training pants 102 ispinched. In such an arrangement, the continuous belt which forms thelower reach 606 of the upper alignment conveyor 256 is translucent andthe continuous belt which forms the upper run 602 of the lower alignmentconveyor is transparent. The translucent belt must be sufficientlytranslucent to allow sufficient light from the radiation source 604 toirradiate the training pants 102 so that the camera behind thetransparent belt is able to capture a clear image of various elements ofthe training pants 102 as it passes through the inspection station. Itis to be understood that the positions of the image capturing device andthe radiation source can be reversed within the scope of the presentinvention.

[0154] A second example of an inspection station in accordance with thepresent invention is illustrated schematically in FIG. 18 in which theupper alignment conveyor 256 and transfer device/scrunch conveyor 430and image capturing device 600 are positioned in the same position as inFIG. 17, but the radiation source 604 is positioned adjacent the imagecapturing device 600. The belt forming the lower reach 606 of the upperalignment conveyor 256 is opaque while the belt forming the upper reach602 of the transfer device/scrunch conveyor remains transparent. In thisembodiment, light from the radiation source 604 is reflected by thetraining pants 102 to be captured by the image capturing device 600.

[0155] A third example of an inspection station in accordance with thepresent invention is illustrated schematically in FIG. 19. In thisembodiment the image capturing device 600 is positioned inside thetubular roller 578 and the light source 604 is positioned above thelower run 606 of the upper alignment conveyor 256. The belt forming thelower reach 606 of the upper alignment conveyor 256 is translucent andthe surface of the roller 578 is transparent. The training pants 102 areilluminated and imaged as they pass through the nip 580 between theupper alignment conveyor 256 and the roller 578.

[0156] A fourth example of an inspection station in accordance with thepresent invention is illustrated schematically in FIG. 20 in which boththe radiation source 604 and the image capturing device 600 arepositioned inside the roller 578 and the belt forming the lower run 606of the upper alignment conveyor 256 is opaque so that the training pants102 are front lit by radiation source 604.

[0157] The image capturing device 600 can be a vision inspection cameracapable of detecting visible and ultraviolet radiation as well asinfrared radiation at wavelengths up to about 1200 nanometers. Forexample, one such device is a charge coupled device (“CCD”) visioncamera available from Sony Corporation of Japan under the modeldesignation XC-75/73. However, it is understood that other imagecapturing devices may used, such as line scan cameras capable ofbuilding an image one line at a time from detected radiation as thepants 102 are conveyed past the device, as well as any other devicecapable of producing a one, two or three dimensional image from detectedradiation, without departing from the scope of this invention.

[0158] The image capturing device 600 may also be provided with a filter(not shown) for filtering unwanted wavelengths of radiation, such asthose in the infrared and/or other spectrums, as desired. Such filtersinclude low-pass filters which remove radiation above a predefinedwavelength, high-pass filters which remove radiation below a predefinedwavelength, band-pass filters which remove all radiation except thathaving a wavelength within a predefined range, and combinations thereof.One or more of these filters may be useful for removing ambient,scattered, or even incident radiation from the image captured by theimage capturing device 600. For example, the image capturing device 600of the illustrated embodiments for detecting infrared radiation candesirably be provided with a filter for removing (i.e., blocking)radiation, such as ambient and/or scattered radiation, having awavelength of or below about 830 nanometers (e.g., a high pass filterhaving a nominal value of about 830 nanometers), including visible andultraviolet radiation. Alternatively (or additionally), one or moreshrouds (not shown) may surround the device 600 to shield the devicefrom, e.g., extraneous radiation sources such as ceiling lights, naturallight, etc.

[0159] The image capturing device 600 is desirably operable to detectinfrared radiation transmitted by the radiation source 604 through thefront and back side panels 34,134 at the engagement seam 88 in thoseembodiments where the light source is opposite the image capturingdevice 600. A two-dimensional image of the engagement seam can then beproduced by the image capturing device 600. As a result, the capturedimage will include variations therein which correspond to variations inradiation intensity (and/or wavelengths) detected by the image capturingdevice 600 from exterior of the pants 102 (e.g., looking at the outsideof the engagement seam 88). In one contemplated form, the image producedby the device 600 is a black-and-white image in which radiation levelvariations are depicted in varying grayscale levels. Alternatively, suchvariations may be depicted in the image in another manner, such as inthe form of color variations. The image capturing device 600 is inelectrical communication with the inspection system control (not shown)and may be operated continuously or it may be shuttered at a speedcorresponding to the intermittent operation of the radiation source 604to irradiate the engagement seam 88.

[0160] The radiation source 604 of the illustrated embodiment iscurrently preferably an infrared radiation source capable of emittingradiation in the near infrared/infrared spectrum (i.e., radiation havinga wavelength between about 700 nanometers and one millimeter). Moredesirably, the infrared radiation source 604 emits radiation in therange of about 700 to about 1200 nanometers.

[0161] In those embodiments where translucent belts are intended to beutilized, it is contemplated that a blended urethane vacuum belt couldbe utilized, such as are available from Midwest Industrial Rubber of St.Louis, Mo., U.S.A.

[0162] Also, the methods and apparatus of the present invention areshown and described herein in connection with making a pair of child'straining pants 20 and inspecting an engagement seam 88 thereof. However,it is understood that the methods and apparatus can be used to make andinspect a variety of articles other than pants 20 where such articlescomprise at least two flexible elements connected together during themaking of such articles in overlapping relationship with other to definean engagement seam. Such articles may include other disposable garmentssuch as diapers, feminine hygiene products, incontinence products, otherpersonal care or health care garments, swim pants, athletic clothing,pants and shorts, as well as other articles, such as balloons, tents,sleeves, cigarette packages, bags, and the like, whether such articlesare disposable or not and whether such articles are absorbent or not.

[0163] It will be appreciated that details of the foregoing embodiments,given for purposes of illustration, are not to be construed as limitingthe scope of this invention. Although only a few exemplary embodimentsof this invention have been described in detail above, those skilled inthe art will readily appreciate that many modifications are possible inthe exemplary embodiments without materially departing from the novelteachings and advantages of this invention. For example, featuresdescribed in relation to one embodiment may be incorporated into anyother embodiment of the invention. Accordingly, all such modificationsare intended to be included within the scope of this invention, which isdefined in the following claims and all equivalents thereto. Further, itis recognized that many embodiments may be conceived that do not achieveall of the advantages of some embodiments, particularly of the preferredembodiments, yet the absence of a particular advantage shall not beconstrued to necessarily mean that such an embodiment is outside thescope of the present invention.

[0164] When introducing elements of the present invention or thepreferred embodiment(s) thereof, the articles “a”, “an”, “the” and“said” are intended to mean that there are one or more of the elements.The terms “comprising”, “including” and “having” are intended to beinclusive and mean that there may be additional elements other than thelisted elements.

[0165] As various changes could be made in the above constructionswithout departing from the scope of the invention, it is intended thatall matter contained in the above description or shown in theaccompanying drawings shall be interpreted as illustrative and not in alimiting sense.

What is claimed is:
 1. A method of inspecting an article with multipleelements to determine if the elements are properly located, the methodcomprising: pinching at least a portion of the article including atleast some of the elements at an inspection station; irradiating thepinched portion of the article and the pinched elements at theinspection station with a radiation source; and capturing an image ofthe pinched, irradiated portion of the article and the pinched,irradiated elements with an image capturing device.
 2. The method ofclaim 1, wherein pinching the article includes positioning the articleat the inspection station so that the radiation source is on a firstside of the article and the image capturing device is on a second sideof the article opposite the first side of the article.
 3. The method ofclaim 2 wherein pinching the article is carried out by first and secondconveyors.
 4. The method of claim 3 wherein pinching the article furtherincludes conveying the article by one of the first and second conveyorsto a nip defined by the first and second conveyors where the article ispinched by the first and second conveyors.
 5. The method of claim 4wherein irradiating the pinched article comprises passing radiation fromthe radiation source through a conveyor belt associated with the firstconveyor to the pinched article, and capturing an image comprisescapturing an image of the pinched article with the image capturingdevice by receiving radiation which passes through a conveyor beltassociated with the second conveyor.
 6. The method of claim 5 whereinthe belt of the first conveyor is translucent and the belt of the secondconveyor is transparent.
 7. The method of claim 1 wherein pinching thearticle is carried out by first and second conveyors.
 8. The method ofclaim 7 wherein pinching the article further includes conveying thearticle by one of the first and second conveyors to a nip defined by thefirst and second conveyors where the article is pinched by the first andsecond conveyors.
 9. The method of claim 1 wherein irradiating theelements includes placing the radiation source on a first side of thearticle and capturing an image includes placing an image capturingdevice on the first side of the article adjacent the radiation source.10. The method of claim 9 wherein pinching the article is carried out bya first conveyor having a belt and a second conveyor having a belt, thebelt of the first conveyor being opaque and the belt of the secondconveyor being transparent.
 11. The method of claim 9 wherein pinchingthe article comprises passing at least a portion of the article througha nip formed by a conveyor and a surface of a roller.
 12. The method ofclaim 1 wherein pinching the article includes passing at least a portionof the article through a nip formed in the area of the inspectionstation by a conveyor and an outer surface of a roller.
 13. The methodof claim 12 wherein irradiating the pinched article comprises passingradiation from the radiation source through a belt associated with theconveyor to the pinched article, and capturing an image comprisescapturing an image of the pinched article with the image capturingdevice from within the roller.
 14. The method of claim 13 wherein thebelt of the conveyor is translucent and the surface of the roller istransparent.
 15. The method of claim 14 wherein the image capturingdevice is positioned inside the roller.
 16. A method of inspecting adisposable pant with multiple fastening components to determine if thefastening components are properly located, the method comprising:pinching at least a portion of the pant including at least some of thefastening components at an inspection station; irradiating the pinchedportion of the article and the pinched fastening components at theinspection station with a radiation source; and capturing an image ofthe pinched, irradiated portion of the article and the pinched,irradiated fastening components with an image capturing device.
 17. Themethod of claim 16 wherein the fastening components comprise portions ofside panels of the pant.
 18. The method of claim 17 wherein thefastening components are engaged to form a lap seam prior to thepinching step.
 19. Apparatus for inspecting an article with multipleelements to determine if the elements are properly located, comprising:means for pinching at least a portion of the article including at leastsome of the elements at an inspection station; means for irradiating thepinched portion of the article and the pinched elements at theinspection station; and means for capturing an image of the pinched,irradiated portion of the article and the pinched, irradiated elements.20. The apparatus of claim 19, wherein the means for irradiating thepinched article and pinched elements comprises a radiation source on afirst side of the inspection station and the means for capturing animage comprises an image capturing device located on a second side ofthe inspection station opposite the first side of the article.
 21. Theapparatus of claim 20 wherein the means for pinching the articlecomprises first and second conveyors disposed adjacent each other andcooperatively engagable with the article to pinch at least a portionthereof.
 22. The apparatus of claim 21 wherein the conveyors arearranged so as to converge toward each other to the inspection station.23. The apparatus of claim 22 wherein the conveyors include continuousbelts which are arranged to cooperatively engage and pinch at least aportion of the article in the inspection station.
 24. The apparatus ofclaim 23 wherein the continuous belt of the first conveyor is interposedbetween the article and the radiation source when the article is in theinspection station and the continuous belt of the second conveyor isinterposed between the article and the image capturing device when thearticle is in the inspection station.
 25. The apparatus of claim 24wherein the belt of the first conveyor is translucent and the belt ofthe second conveyor is transparent.
 26. The apparatus of claim 19wherein the means for pinching the article comprises first and secondconveyors disposed adjacent each other and engagable with opposite sidesof the article to pinch at least a portion thereof.
 27. The apparatus ofclaim 26 wherein the conveyors are arranged so as to converge towardeach other to the inspection station.
 28. The apparatus of claim 27wherein the conveyors include continuous belts which are arranged tocooperatively engage and pinch at least a portion of the article in theinspection station.
 29. The apparatus of claim 19 wherein the means forirradiating the elements comprises a radiation source and the means forcapturing an image comprises an image capturing device, the radiationsource and image capturing device being located on the same side of theinspection station.
 30. The apparatus of claim 29 wherein the means forpinching comprises first and second conveyors each including a conveyorbelt, the belt of the first conveyor being opaque and the belt of thesecond conveyor being transparent, the radiation source and the imagecapturing device being located on an opposite side of the belt of thefirst conveyor from a side facing the belt of the second conveyor. 31.The apparatus of claim 29 wherein the means for pinching the articlecomprises a roller and a conveyor disposed adjacent the roller to definea nip to pinch the article as it passes therethrough.
 32. The apparatusof claim 29 wherein the conveyor comprises an opaque belt and thesurface of the roller is transparent.
 33. The apparatus of claim 32wherein the radiation source and image capturing device are located onan interior of the roller.
 34. The apparatus of claim 19 wherein themeans for pinching comprises a roller and a conveyor arranged relativeto the roller to define a nip to pinch the article as it passestherethrough.
 35. The apparatus of claim 34 wherein the conveyorincludes a continuous belt disposed between the radiation source and theroller and wherein at least a surface of the roller is disposed betweenthe image capturing device and the continuous belt.
 36. The apparatus ofclaim 35 wherein the belt of the conveyor is translucent and the surfaceof the roller is transparent.
 37. The apparatus of claim 36 wherein theimage capturing device is positioned inside the roller.
 38. Apparatusfor inspecting an article with multiple elements to determine if theelements are properly located, comprising: a conveying system forming anip through which the article passes and which is so constructed andarranged as to pinch at least a portion of the article and at least someof the multiple elements as they pass therethrough; a radiation sourcedisposed adjacent the nip and which is mounted and arranged so as toirradiate the at least a portion of the article and at least some of theelements as they pass through the nip; and an image capturing devicedisposed adjacent the nip and which is mounted and arranged so as tocapture an image of the irradiated at least a portion of the article andat least some of the elements as they pass through the nip. 39.Apparatus for inspecting two substantially mirror image side portions ofan article each side portion having multiple elements to determine ifthe elements are properly located, comprising: a conveying systemforming a nip through which the article passes and which is soconstructed and arranged as to pinch at least the side portions of thearticle and at least some of the multiple elements on each side portionas they pass therethrough; a pair of radiation sources each disposedadjacent the nip and each of which is mounted and arranged so as toirradiate a respective one of the side portions of the article and atleast some of the elements associated with the respective side portionas they pass through the nip; and a pair of image capturing devices eachassociated with a respective one of the radiation sources and disposedadjacent the nip and which are mounted and arranged so as to capture animage of the irradiated respective side portion of the article and theassociated elements as they pass through the nip.